4 ATSG INTRODUCTION HONDA CIVIC 3 SHAFT M24A This Booklet covers the 3 shaft Honda unit that is found in the Civic models. Although at first glance you will see solenoids on this unit, it is not a computer controlled shifting model. The solenoids are for the converter clutch engagement. This unit is hydraulically controlled. This manual covers the remove and replace of the Unit from the vehicle. The tear-down and assembly and a trouble shooting section. Again it is important to know which model you are working on. In the area on the transmission where the serial number is located it will show the model number, which is M24A. We thank HONDA for the illustrations and information that have made this booklet possible This information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee the accuracy. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL SUPERVISOR ED KRUSE PETE LUBIN LAYOUT TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 7 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 (305) 670-4161IW@ATSGI. 3% ee, ATIC TRANSMISSION SERVICE ou) eo INDEX Description.. Hydraulic Control ‘Troubleshooting... Transmission Removal. Wlustrated Index... Teardown........ Valve BOdy.seseeve Governor. Mainshaft...... Countershaft. a Sub-shaft.... = 74 Clutch Packs. sessenseenseaeinseneess 76 Differential. ene Reassembly. Installation. Linkage. 102 Automatic Transmission Service Group 9200 South Dadeland Blvd. Suite 720 Miami, FL 33156 (305)'670-4161EM ATSG] Technical Service Information Description The automatic transmission is a combination of @ 3-element torque converter and triple-shaft automatic transmission which provides 4 speeds forward and 1 reverse. The entire unit is positioned inline with the engine, Torque Converter Gears and Citches The torque converter conse of pump, turbine and soto exsemby na singlunit. The torque converte is connected tthe engine cronkshat so they tum together 8 uit s the engine ture, Around the ose ofthe traue converte rng geet ‘eich maches withthe strtr prion when the angie fy belo strtad. The ene torque converter aseembly teres 8 Trwieel whe trenemiting power fo the onemisin manchalt Tho tronemission hes threo paral shafts, the mainshat,countrshat and sub shat, The mainshatt isin ne withthe engine crankahet The manshaft inches th clutches for Ts, ond 2nd/4th, and gears for Sr, nd, Ah, reverse and 1st (4 goa is iteorl with theminshft whe reverse goa integral with the th goa). ‘The countershaft inchides the 3rd clutch and gears for 3rd, 2nd, 4th, reverse, 1st and parking. Reverse and 4th gears can be locked to the countershatt tits center, proving th gear or everse, depending on which wa the selectors moved, ‘The subshatinces the 1st hold latch and gear for To and th ‘The gers on tho moinshat rein constant mesh with these on the countershaft and sub-shaft, When certain combinations of oars nthe tongs oe engaged by tho ltches, power i ransnted om th meinhat oth countershef vi the sub Shae to provi De [D3]. [21-11 Jona poston Hydraulle Control ‘The valve bodies include the main valve body, secondary valve body, regulator valve body, servo body, modulator valve body, lock-up valve body, and governor body, through the respective separator plates. “They are bolted on the torque converter housing. 41-2 shift valve, 2:3 shift valve, 3-4 shift valve, 3-2 timing valve, 4th exhaust and ol pump goa ‘The secondary valve body contains the 4-3 kick-down valve, 3-2 kick-down valve, 2-3 orifice control val Clutch Pressure Control (CPC) valve, servo control valve, reverse control valve, and governor cut valve. ‘Tho regulator valve body contains the pressure regulator valve, lock-up control valve, torque converter check valve, and cooler check valu The servo body contsins the servo valve which is integrated with the reverse shift fork, throttle valvas A and B, 2/3-4 orifice control valve, and accumulators. ‘The modulator valve body, which is bolted on the servo body, contains the modulator valve. The lock-up valve body contains the lock-up shift valve and lock-up timing B valve, and is bolted on the secondary valve body. The governor body is bolted on the torque converter housing near the differential. Fluid from the regulator passes through the manual valve to the various control valves. 241 timing valve, Lock-up Mechanism tn[_D4 |, in 2nd, 3rd and 4th, end{ Dain 3rd, pressurized thd is drained from the back of the torque converter through an oil ‘passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the msinshaft rotates at the same speed as the engine crankshaft. Together with hydraule control, the engine control madule (ECM) optimizes the timing of the lock-up mechanism. The lock-up shift valve controls the range of lock-up according to the lock-up control solenoid valves A and B, and throttle valve B. The lock-up control solenoid valves A and B are mounted on the torque converter housing, and are controlled by the ECM, (cont'a)Technical Service Information [-] VEHICLE SPEED SENSOR (VSS) DIFFERENTIAL ‘GOVERNOR BODY SRD CLUTCH MAINsHAFT sua-sHAFT 'STHOLD CLUTCH THROTTLE CONTROL CABLETechnical Service Information Ys | r Clutches ‘The four speed automatic transmission uses hydraulically actuated clutches to engage or disengage the transmission gears, When clutch pressure is introduced into the clutch drum, the clutch piston is applied. This presses the friction dises and stool plates together, locking them so they don’t slip. Power is then transmitted through the engaged clutch pack to its hub-mounted ee Likewise, when clutch pressure is bled from the clutch pack, the piston releases the friction discs and steel plates, and they ar {ree to side past each other while disengaged. This alows the gear to spin independently ofits shaft, transmitting no power. tet chuteh ‘The 1st clutch engages/cisengages 1st gear, and is located at the ‘The 1st clutch is supplied clutch pressure by its ol ‘etchold Clutch = The Ist-hold clutch engages/cisengages 1st-hold or [7] position, and is located at the center of the sub-shaft. The tst-hold clutch is supplied cutch pressure by its ol feed pipe wiffin the sub-shatt. 2nd Cutch The 2nd clutch engages/disengages 2nd goar, and is located at the center of the msinshaft. The 2nd clutch is joined back-to- back to the 4th clutch. The 2nd clutch is supplied clutch pressure through the mainsheft by 8 circuit connected to the regulator valve body. 3rd Clutch ‘The Grd clutch engages/disengages 3rd gear, and is located at the end of the countershaft, opposite the right side cover. ‘The 3rd clutch is supnied clutch pressure by its ol fed pipe within the countershatt. 4th Clutch ‘The 4th clutch engages/disengages 4th gear, as well as raverse gear, and is located at the center of the mainsha, ‘The 4th clutch is joined back-to-back to the 2nd etch. The 4th clutch is supplied clutch pressure by its oll feed pipe within the mainshatt. One-way Citch The one-vay cich is postioned between the parking gee and 1t gear, with the perkng ger splined to the courtershat. The tst gor provides the outer race, and the paring gear provides the ner race surface. The one-way chitchWcks UP when power'stanemited rem the malnshatTst ger tothe counteroatt 1 gear The ts clutch and gears remain engaged inthe 18, nd, 3 and th gear ranges in te[ Be]. [Ba Jor[Z]ostion. However, the one-way clutch disengages when the 2nd, 3rd, or 4th clutches/gears are applied in the| Ds ,[ Da Jor| 2] position. This is because the increased rotational speed of the gears on the countershaft over-ride the locking “speed range” of the one- way clutch. Thereafter, the one-way clutch free-wheels withthe Ist clutch stil engaged. COUNTERSHAFT 1ST GEAR Locks ay Locks FREE PARKING GEAR NOTE: View from right side cover side.(cont'd) Th Technical Service Information Gear Selection sor nver a evan gosto [F pant [RI] ReVERSE, [W]NEUTRAL [Be] tosh postons [Bs Ist through 3rd positions, | 22nd gear and 1 ‘st gear. Fst through 4th) Da JORIVE Fist through Sra Postion Description F]PARK Front wheels locked: perking pawl engaged with paring gear on countershat. Alcitches releesed [RJreverse [i]weurnan | Avcutches coleased. [BeJonwe | Ganeratdving: starts oft inte, shits automaticaly to 2nd, Sr, then Ath, depending on vehicle speed ‘and throttle position. Downshifts through 3rd, 2nd and Ist on deceleration to stop. ‘The lock-up mechanism comes into operation in 2nd, Srd and 4th when the transmission in [ Ds position For rapid acceleration at highway speads and general driving; starts off in tst, shifts automatically to 2nd then 3rd, depending on vehicle speed and throttle position. Downshifts through lower gears on ‘deceleration to stop. The lock-up mechanism comes into operation in 3rd. T]}secono | rivingin and gear; stays in 2nd gear, doesnot shift up and doven. For engine braking or better rection starting off on loose or sippery surece [ijest — | wing in tt gar saysin te goer, des ot shit wn. For engine braking. | Power Flow. pant] Tongue] ier ]isv ceanlanoceadano cea arm REvERse] ances GON. | How | ist. | ND.) 38D. an | GEAR Poston vEnter | cturen| cLurcn| cLUTcH| cuUreH | GEAR | CLUTCH ? O x |» |x«ti{«i]~« fo Rk oO x x x x Oo fe} x N oO x F x x x x x x x 1st ° x ° x x |x x x x 2ND Oo x oO x x x x x aD O x | o | x ieee ae aTH ° x |x [Tofolfx | « 1st Oo a x x a x x x [ey |__ 20 of[ =x fololf «x x |x |™«|~x 3AD oO x *O ; x Oo x x x x 7 oO x *O oO x x x x ° o fo x x x x x x sips. (©: Operates, x: Doesn't operate, *: Although the Ist clitch engages, diving power is not transmitted as the one-way clutchATSG Technical Service Information 7 | i SUB-SHAFT MAINSHAFT 3AD GEAR sue star MAINSHAFT 2ND GEAR gT-HOLD cLUTCH J TORQUE CONVERTER Pere : sussHarT FING GEAR eer Ssrcean STHIREVERSE elarey EAR sue-sHAFT cure = | MAINSHAFT YSTGEAR ra ‘1 PUMP LL asrwurcH DRIVE PLATE MAINSHAFT FINAL ORIVE- (COUNTERSHAFT. GEAR ‘PARKING GEAR ONE-WAY CLUTCH ‘COUNTERSHAFT 187 GEAR (COUNTERSHAFT REVERSE GEAR REVERSE SELECTOR REVERSE SELECTOR HUB ‘COUNTERSHAFT 4TH GEAR ‘COUNTERSHAFT 2ND GEAR COUNTERSHAFT 3RD GEAR ‘ano cluTcH FINAL DRIVEN GEAR DIFFERENTIALATSG Technical Service Information r Hydraulic Control The /e bodies include the main valve body, secondary valve body, regulator valve body, servo body, lock-up val governor body and modulator valve body. ‘The oil pump is driven by splines behind the torque converter which is attached to the engine. Oil lows through the regulator valve to maintain specified pressure through the main valve body to the manual valve, directing pressure to each of the chitches. RIGHT SIDE COVER SERVO BODY SECONDARY. ‘VALVE BODY REGULATOR VALVE BODY" MAIN VALVE BODY GOVERNOR BODY OL PUMP GEARS Lock.uP confrot ‘z= SOLENOID VALVE ASSEMBLY ‘TORQUE CONVERTER HOUSINGATSG Technical Service Information Main Vaive Body ‘The manual valve, 1-2 shit valve, 2-3 shift valve, 9-4 shitt valve, 4th exhaust valve, 3-2 timing valv ‘assembled inthe main valve body. ‘The primary function of this valve body is ewitching oll passages on and off and controling the hydraulic pressure going to the hydraulic control system. and relief valve are all 2.3 SHIFT VALVE, 344 SHIFT VALVE Ses RELIEF VALVE MANUAL VALVE 1-2 SHIFT VALVE MAIN VALVE BODY ‘Secondary Vaive Body ‘The secondary velve body is loceted on the main valve body. The 3-2kick-down valve, 4-3 kick-down valve, 2:9 orifice control valve, governor cut valve, 2-1 timing valve, reverse control valve, servo control valve, and clutch pressure control (CPC) valve fare assembled in the secondary valve body. 4-3 KICK-DOWN eae GOVERNOR CUT VALVE 2-2 KICK-DOWN 2.3 ORIFICE CONTROL VALVE VAUvE ra Sy zi Tmne vaive : ty oe Qe RY SECONDARY VALVE BODY Pc valve ‘SERVO CONTROL VALVE (con's)Technical Service Information r Hydraulic Control (cont’d) Servo Body ‘The servo body is located on the secondary valve body. The servo valve which is integrated with the shift fork shaft, throttle valve A and B, 2/3-4 orifice contro! valve, and ‘accumulator pistons are all assembled in the servo body. Modulator Valve Body ‘The modulstor valve body with the modulator valve is located on the servo body. MODULATOR YALVE BODY MODULATOR VALVE 213-4 ontrice CowrroL VALVE SERVO VALVE! ‘SHIFT FORK SHAFT THROTTLE VALVES ‘SERVO BODY jody 1¢ body is located on the main valve body. The regulator valve body consiste of the regulator valve, torque /e, cooler check valve, and lock-up control valve. REGULATOR VALVE REGULATOR VALVE BODY (COOLER CHECK VALVE LOCK-UP CONTROL VALVE onauE conveRTER CHECK VALVETechnical Service Information Regulator Valve The regulator valve maintains a constant hydraulic pres furnishing ol!to the lubricating system and torque converter. Oil flows through B and 8’. The oll which enters through B flows through the valve orifice to A, pushing the regulator valve to the right. According to the level of hydraulic pressure through B, the position of the valve changes, and the amount of the oil through 8’ from D thus changes. This operation is continued, thus maintaining the line pressure, re from the oll pump to the hydraulic control system, while also ENGINE NOT RUNNING) (eNGwe RUNNING) To TORQUE CONVERTER STATOR SHAFT an ! 2 io Stator Reaction Hydraulic Pressure Control Hydraulic pressure increase, according to torque, is pertormed by the regulator valve using stator torque reaction, The stator shaft is splined to the stator and its arm end contacts the regulator spring cap. When the car is accelerating or climbing (Torque Converter Rangel, stator torque reaction acts on the stator shaft and the stator shaft arm pushes the regulator spring cap in this direction in proportion to the reaction. The spring compresses and the regulator valve moves to increase the regulated ‘control pressure or line pressure. Line pressure is maximum when the stator reaction is maximum. REGULATOR VALVE REGULATOR SPRING CAP, stator: {inside torque converter) STATOR SHAFT ARM STATOR SHAFT (cont'a)r Hydraulic Control (cont’d) Lock-up Valve Body ‘The lock-up valve body with the lock-up shift valve LOCK-UP SHIFT VALVE Lock.up vaLve BODY Accumulator Pistons The accumulator pistons are assembled in the 1ST.HOLD ACCUMULATOR PISTON FIGHT SIDE COVER ‘4TH ACCUMULATOR PISTON. 1ST ACCUMULATOR PISTON: .2ND ACCUMULATOR PISTON ‘3RD ACCUMULATOR PISTON Technical Service Information 1 lock-up timing B valve is located on the regulator valve body. Lock. ur TIMING B VALVE rv body and right side cover. The tst-hold clutch accumulator piston isin the Fight side cover, ané the tst, 2nd, 3rd, and 4th accumulator pistons are assembled in the servo body. ‘SERVO BODYATSG Technical Service Information Hydraulic Flow General Chart of Hydraulic Prossure Line Pressure Ol Pump—> Reguatar Valve ->| Torque Converter Pressure Lubrication Pressure Distribution of Hydraulic Pressure 1 Pressure Lubrication Pressure seminar vive af ‘+ Monual Valve > To Select Line Pressure ‘* Modulator Valve > Modulator Pressure e12shit i] =23 Shift Valve 23-4 Shift Vi > Clutch Pressure ‘Throttle Valve A > Throttle A Pressure ‘Throttle Valve > Throttle B Pressure ‘Governor Valve > Governor Pressure NO. | BESCRPTIONOF PRESSURE | NO. | DESORPTIONOF PRESSURE | _NO. | _DESCRPTION OF PRESSURE 7 [| ene 16_| 1sTHOLDcLUTCH o7_| TeRoTTee 2 | une 1 | une we | tHrormes 3 | une | awocuTcH [60 | Governor 3 | LINE 21 | 2NDCLUTCH | 61 | GoveRNoR a LINE 25 LINE | 90 | TORQUE CONVERTER: 4 [une 3o_| eno cLuToH e1_| Tonave cowvenTeR [ene ai_| aro cLUTCH 32_| TORQUE CONVERTER 5 LINE. 40 ‘4TH CLUTCH | 93 Ol COOLER: 5 | une a | atHcuuTcH ea_| TORQUE CONVERTER 5 | une =| THROTTUEA 96 | LUBRICATION 6 | MoouaTor ot | THROTTUEA 36 | TORQUE CONVERTER @ | MODULATOR s2_| THROTTLEA [97 _| ToRaue cowvenTER 10 | ssTcuuTcH 6 | THROTTLE® [99 [ suction 16 | terHoLo cLUTEN we | THrotriee [oe [meen (cont'd)Technical Service Information r Hydraulic Flow (cont'd) N]Position AS the engine turns, the oil pump also starts to operate. Automatic transmission fluid (ATF) is drawn from (99) and discharged. into (1). Then, ATF pressure is controled by the regulator valve and beBomes ine pressure (1). The torque converter inlet pressure (92) enters (94) of torque converter through the orifice and discharges into (90), “The torque converter chack valve prevents the torque converter pressure from rising, Under this condition, the hydraulic pressure is not applied to the chtches.Technical Service Information r Lock-up System tn[ +] or [Dain 2nd, se and 4th, pressurize tid serine trom the back ofthe toraue converter through anol pessege, calising th Tock-up piston to beheld against the torque converter cover. As this takes place, the malnwhett rotates atthe samo speed as the engine crankshaft, Together with hydrauic control the ECM optimizes the timing of the lock-up syetom, Under Certain conditions, the lolcup operation sapped during decelertion, in 2nd, Sd an Ath spe ‘The lock-up shift valve controls the range of lock-up according to lock-up control solenoid valves A and B, and the throttle valve, When lock-up control solenoid valves A and B activate, modulator pressure changes. Lock-up control solenoid vaives A and B ‘are mounted on the to-que converter housing and are contralled by the ECM. From sensor input signels, the ECM detects whether to turn the lock-up ON or OFF and activates lock-up control solenoid valve Aandior 8 accordingly. ‘The combination of driving signals to lock-up control solenoid valves A and Bis shown inthe table below. Solenoid valve A 8 Lock-up condition Lock-up OFF OFF OFF Lock-up, sight ‘ON | Duty operation ‘OFF +> ON Lock-up, half oN oN Lock-up, ful oN on Lock-up ON | Duty operation ring deceleration OFF > ONTechnical Service Information Troubleshooting Hf the lock-up control system is suspected to be faulty, do the folowing: 1. If the Melfunction Indicator Lamp (MILY/ Check Engine Light comes on, check and inspect PGMI system according to PGMFI Troubleshooting NoTE: PGMF system ‘The PGMI system on this models a sequential multiport fuel injection eyster, Usa CANADA MALFUNCTION CHECK ENGINE LIGHT INDICATOR LAMP (ML) 2, Ifthe Meifunction indicator Lamp {MIL} Check Engine Light does not come on ot it blinks other than nineteen times (while connecting the Service Check Connector terminals with a jumper wire), check and inspect according to the Symptom-to- Component Chart 3. Check the lock-up control solenoid valver Test NOTE: LLock-up control solenoid valves A and B must be removed! replaced as an assembly. 1. Disconneet the connector from the lock-up control solenoid valve A/B. 2. Measure the resistance between the No. 1 terminal (solenoid valve Ab of the lock-up control solenoid valve ‘connector and body ground, and between the No. 2 ‘terminal (solenoid valve B} and body ground. STANDARD: 14~25 0 pisTRIByTOR Lock-uP conTROL SOLENOID VALVE ASSEMBLY the lock-up control solenoid valve assembly if existance is out of specification. 4, Ifthe resistance is within standard, connect the No. 1 terminal of the lock-up control solenoid valve connector to the battery positive terminal and body ground. A clicking sound should be heard. Connect the No. 2 terminal to the battery positive terminal end body ground. A clicking sound should be heard. 5. Replace the lock-up control solenoid valve assembly if 'no cicking sound is heard Technical Service Information Lock-up Control Solenoid Valve A/B - Replacement 1 Remove the mounting bolts and lock-up control solenoid valve assombly. NoTE: Be sure to remove or replace the lock-up control solenoid valves A and 8 as an assembly. ‘Check the lock-up control solenoid valve oll passages for dust or dir, and replace as an assembiy, if necessary. 8x1.0mm 12 Nem(1.2 kom, 9 Bett Lock-uP conTRoL SOLENOID VALVE ‘surface and of Cad passages, FILTERIGASKET Replace. Clean the mounting surface and oll passages of the lock-up control solenoid vaive assembly and install 3 ew fiter/gasker. Check the connector for rust, dirt or oll and reconnect itsecurely.ATSG Technical Service Information Hydraulic System -- Symptom-to-Component Chart Check these items on the ‘At disassembly, large particles of metal are found on magnet. syweTom NOTES CHART Engin ran, but ar does not move any gear ELAS Car moves inR and 2, But notin Ds, Der CMO Car moves ia, Os, 1, but not 2 — Cer moves inDa-be.2.1 but not n Ca. ‘Cor moves nN co Excessive ile Bran aeL Sips inal gare CU: No engine braking pasion Cot Sips in tet CNOT Sips in dnd gear CLU: Sips in ard pose CUU Sips sth gear cy Sips ineverse gear c Flares on 1-2 psn Ly Flares on 2-3 ups ety [Flores-on 5:4 ups ev No upshift, transmission saya in Tat paz er No downif to low gear et bate upshit. cv Erratic shiting ¥ ah sf (op ane down sig) TAERILY Harsha (12. Te o.v Harsh anf (23) COMLY Marsh sit (9) = eBLLY Harsh kick down is Lvid ‘Harsh kick-down shift (2-1). o Harsh downshift at closed throta eT Harsh shift when manvaly shifting fT t ‘els sigs out of wansmason on turns Leo ‘ales stock in transmission, td ‘Ratcheting noise when shifting into R. Kt O Lod popping noe when taking off in ud Fiatcheting noise when shiting from R to PortromATaN_| 38.39, 40,45 ta [Ceise from tranusson inal selector lever postions. 1-6, 17 KL Noise ftom transmssion ony when wheels are rong. 198, «2 uo ‘Gear whine, fom rested itch changes with shifts) a 41 Lo ‘Gear whine- speed related (pitch changes with spaedl 198, 47 Lo “rangmisson wil not shitinte 4th gear in Os 121, Ee Lock-up utch dogs not lock-up smoothly 17,38,37 = Lock:up clutch doesnot operate proper 2.5, 16, 18,55, 36,57 ELV ‘fanamion has mulitoce of problems ehfTha 38 tdTechnical Service Information PROBABLE CAUSE ‘Shift cable broken/out of adjustment, “Throtte cable t00 short. | “Throttle cable to0 ong. Wrong type ATF. idle rpm too low igh ‘Oilpump worn or binding. Regulator valve stuck, Ist clutch defective ‘nd clutch defectiv ‘3rd clutch defective. 4th clutch defective. ist-hold clutch defective. Modulator valve stuck, “Throttle valve B stuck TATE strainer clogged. “Torque converter defective “Torque converter check valve stuck, 5-2 shift valve stuck, 23 shift valve stuck. ‘3. shift valve stuck. ‘Servo control vaive stuck ‘Cutch pressure control (CPCI valve stuck. 23 orfice control valve stuck. 213-4 orice control valve stuck 3.2 kick-down valve stuck {>| nfn fsfo 27. [4-3 kick-down valve stuck. 28. [ath exhaust valve stuck. 23, ‘st accumulator defective. = '30._—| “nd accumulator defective. Kil ‘3rd accumulator defect 32, [4th accumulator defective 1 33, ist-hold accumulator defective 34.1 Serve valve stuck. 35 Lock-0p timing valve stuck, 36. Lock-up shift valve 97. | Lockcup control valve stuck. ‘38. Shift fork bent. ‘39. |“ Reverse gears worn/damaged (3 gears] 40. = | a1 42. | Final gears worn/damaged (2 gears) 43 Differential pinion shaft worn, 43. Feadpipe O-ring broken. 45. | ath gears worn/damaged (2 98873), 46. Gear clearance incorrect, = 47, [Clutch clearance incorrect. ‘48. | One-way ispragi clutch dofectiv ‘49, | Sealing rings/quide worn, : 50. | Axlesinboard joint clip missing (cont’a)Technical Service Information r Symptom-to-Component Chart (cont'd) ——___________ The folowing symptoms can be caused Check these items on the ‘res on the ] ‘by improper repair or assombly. PROBABLE CAUSE DUE NOTES CHART TO IMPROPER REPAIR Car craps InN RI, R2 (Gar does not move in Da or Ds, Ra “Transmission locks up in F. R3_RIZ Re KR : R7 RS. RB. = 9, ATO, Rit PROBABLE CAUSE DUE TO IMPROPER REPAIR, Tinpropar Gutch clearance. clearance. ever instaled upside down. (spragl clutch installed upside down. Reverse selector hub instaled upside down. ‘Oilpump binding. forque converter not fuly 32 Main seal improperly stated ‘Springs improperly installed, Valves improperly installed, Bail check vaives not instaled, [Shift fork bottnot installed: 1 edo pu,ATSG Technical Service Information Notes [een ‘See flushing procedure, page. B. Set ile rpm in gear to specified Wie speed. WSN no 960d, BER MOTOT MoUs Be OUT Heroine BBGTON of service manual C: 1 the large clutch piston O-ring is broken, inspect the piston groove for rough machining. D. | “the clutch pack is seized or is excessively worn, inspect the other clitches for wear ahd GhEck the orice Control valves and throttie valves for free movement. E H throttle valve Bis stuck, Inspect the cutches for waar. | the 12 shift valve is stuck closed, the transmission wilfot upanift, Watuck open, the Transmission Fas Ao Ist gear F F the 2—3 ofifce control valve ls stuck, apect the Znd and Sra chech packs Yor Waar i Wthe 2°3—4 orfice control valve is stuck, inspect the 3rd and 4th clutch packs for wear. SE Ifthe clutch pressure control valve (CPC) s stuck closed, the transmission wil not shift out of Tet gear K._|~ Improper alignment of main valve body and torque converter housing may cause oll pump seizure, The ‘symptoms are mostly an rpm-related ticking noise or a high pitched squeak. C ifthe ATF strainer is clogged with particles of steel or aluminum, inspect the Ol pump and aiferential avon shaft. f both are OK and no cause for the contamination is found, replace the torque converte. Wt H the Tst clutch feedpipe guide in the right side cover is scored by the mainshaft, inspect the bal bearing Tor excessive movement inthe transmission housing, if OK, replace the right side cover as ts dented. “The O-ring under the guide is probably worn. Ww. Replace the mainshaft ifthe bushings for the Tst and 4th feedpipa are loose or damaged. W the "st Teeapine & | damaged or out of round, replace it. Ifthe 4th feedpine is damaged or out of round, replace the right side 6. ‘A worn or damaged one-way spraql clutch is mostly a result of shifting the wansmiasion in Da 01 De while The ‘wheels rotate in reverse, such as rocking the car in snow. F. inspect the frame for colision damage, a: inspect for damage or wi 1. Reverse selector gear teeth chamfers. 2 Engagement teeth charters of countershaft 4th and reverse gear. 43. Shift fork for scuff marks in center. 4. Differential pinion shaft for wear under pinion gears. | 5. Bottom of 3rd clutch for switl marks. Replace items 1, 2, and 4 if worn or damaged. if transmission makes clicking, srinding or whirring noise, also Feplace mainshaft 4th gear and reverse idler gear and countershatt 4th gear in ailtion to 1.2. 3.0r 4. I differential pinion shaft is worn, overhaul differential assembly and replace ATF strainer and thoroughly clean transmission, flush torque converter, cooler and ines, {f bottom of 3rd clutch is swirled and transmission makes gear noise, replace the countershatt and final driven gear | om ‘Be very careful not to damage the torque converter housing when replacing the main ball bearing. You Way ‘also damage the oll pump when you torque down the main valve body, This will result in oi pump seizure i hot detected. Use proper tools Tnstall the main seal flush with the torque converter housing. W'you push Rt Into the toraue converter hovsing Lntilt bottoms out, it wil block the oll return passage and result in damage. T. Hersh downshifts when cossting to a stop with zero throttle may be caused By @ bantin throtle vaNe ‘etainer/cam stopper. Throttle cable adjustment may clear this problem. ‘Check if separator plate is installed. fit was not installed, the servo valve may have been pushed out By hydraulic pressure causing a leak (internal) affecting all forward gears, Z Vv. Throttie cable adjustment is essential for proper operation of the tranamission. Not only does W affect the shift points if misadjusted, but also the shift quaity and lock-up clitch operation. | ‘A cable adjusted too long wil resut in throttle pressure being too low for the amount of engine torque input into the transmission and may cause clutch sippage. A cable adjusted too short will result in too high throttle Dressures which may cause harsh shifts, erratic shifts and torque converter huntingTechnical Service Information EJ Road Test NoTe: ‘Warm up the engine to operating temperature (the cooling fan comes on 1. Apply parking brake and block the wheels. Start the engine, then move the selector ever to Ds ] position while depressing the brake pedal. Depress the accelerator pedal, and release it suddeniy. Engine should not stall 2. Repeat samo test in{ Ds | position. 3, Shift the selector lever to Ds ] position and chock that the shift points ocour at epproximate speeds shown. Also check {for abnormal noise and clutch slippage. NOTE: ‘Throttle position sensor voltage represents the throttle opening =1. Connect the Test Harness between the ECM and connector (see section 11). 2. Set the digital muttimeter to check voltage between D11 (+) terminal and D22 (—) terminal for the throttle position DIGITAL MULTIMETER KS-AHM32-003 ‘Test HARNESS OTAJ—PT20108, pif 22ATSG Technical Service Information 1D1887 engine: De Jor[ Ds [Position Upshift Throttle Opening Unit of speed Teta tae Bnd > Sea Tas ah. Fuaclosed throttle Kr 15=19) 35=39 49=53 mph S=12 226 30=33 “Throttle position sensor Ken 0=24 45=49. 63=69. voltage: 1.27V. mph. 42=15 2830 39— 43 ‘Throttle position sonsor Km 25=33 5769 ‘s0= 92. voltage: 203V mph. [——16=21 35=43 50=57, Fulropened throws Km [49= 85, 92=99 746=187 mph [amma = ee B62 31= 98. ‘= Downshitt Throttle Opening, Unit of speed at Sea Sd and Bnd > Tat Fuiclosed throttle Keni — 29-33 9=13 mph —— 48=21 68 Faropened throttle [eri 124— 135, 592 w=45 mph T=B4 53-87 26—23 * Lock-up Throttle Opening Tait oF ap Da Position. Da Position TeckupON | Locicup OFF | Lodk-up ON |" Lock-up OFF Fuclosed throwle Ka 24—27 2326 ‘97103 ‘92—98. mph. 117 1a=16 ‘60=64 =61 Throttle position sensor Km 307=13 w=93 ‘92=98 voltage: 203V, mph 66=70. a= 58. 3761 FuFopened howe Ken qai=14, Tag= 1a a2= 138 | “126= 13 moh 88=31 588 8286 7e=82 (cont'd)Technical Service Information r (cont’d) 101626 engine:| De Jor[Da | Position + Upsnite “Throttle Opening ‘Unit of speed | Ist > 2nd ‘2nd = 3rd ard > 4th Fulrclosed throttle Km/h T 15=19 35-39, cio sun 1 aa 3083 “TROT FERRIS SORE eh} a= = vonage: 1270 oh as [an = fa Baa = Trane postion sneor sea merase e278 w=08 voroge, 2090 saat 3346 =e For ened OTe ees meer e813 Tee= 168 op} 8s co=70 S=T6S * Downshitt Taree Opa Talat oped aaa Tero ase Ful-closed throttle Kmih_ = 33 3—13 mph teat =e | rarspenerroTIE a Tats BE=102 =a Teh Baae B=0e S27 Lockup Throttle Opening Unit of speed (Ds Position Ds Position Tockuap ONT Loccup OFF | Tasicup ONT Lockap OFF Fabaceae ah Soy tae | estos | aoe or te=17 | —te=1e_|_ t0=68_| 7m ar | rirane paar snsor on rte} —w=88 | Tors | 888 voto 2590 or o=70 | aes | —es=90 | — aye Hee tron a Weare} taster | ep tee |= ta oh a a 4, Accelorate to about 36 moh (57 kmh) so the transmission i in th, then shift [De] to [2]. The ear shoul immesatey begin slowing down from engine braking, CAUTION: Do not shift from[ Ds Jor[ Da }to[ 2 Jor{ 1] at speeds over 100 mph (160 km/h: you may damage the transmission. '. Check for abnormal noise and clutch sippage in the folowing positions. [11] (18t Gean Position =. Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch sippage 2. Upshifts should not occur with the selector in this position 2 |\2nd Gear) Position =1. Accelerate from # stop at full throttle. Check that there is ne abnormal noise or clutch slippage. =2, Upshifts and downshifts should not occur with the selector in this position. Ri | (Reverse) Position ‘Recolerate from a stop at ful throttle, and check for abnormal noise and clutch slippage. 6. Testin[F] Parking) Poston slope lanprox. 16°), apply the parking brake, and shift nto] postion. Release th brake: the car should notTechnical Service Information Stall Speed r Test CAUTION: * To prevent transmission damage, do not test stall speed for more than 10 seconds at atime. ‘Do not shift the laver while raising the engine speed. '2ure to remove the press before testing stall speed. 1. Engage the parking brake and biock allfour wheels. 2. Connect the tachometer, and start the engine. 3, Make sure the A/C switch is OFF. _ 4. After the engine has warmed up to normal operating temperature (the cooling fan comes onl, shift into[ 2] position. 5. Full depress the brake pedal and accelerator for 6 to 8 seconds, and note engine speed. 6. Allow 2 minutes for cooling, then repeat the test in[ 1 |.[ De and] R J positions. t8 should be used for agnostic pressure only De].[2].(1 ]ana[ R J positions. TROUBLE PROBABLE CAUSE. ‘Stallrpm high in[D«],[2].L1]ena[R] | - Low fluid ievelor of pump output position * Clogged ATF strainer + Pressure regulator valve stuck closed Slipping ckstch ‘Stallrpm high in 1 | position + Slippage of 1st clutch, 1st-hold clutch or 1st gear one-way clutch ‘Stallrpm high in[2 | position + Slippage of 2nd clutch. ‘Stall rpm high in| Ds | position + Slippage of 1st clutch, 1st gear one-way clutch | ‘tallrpm high in[ R ] position + Slippage of 4th clutch Stallrpmiow in[ De],[2],[1]ana[R] | - Encine output low position Torque converter one-way clutch slippingTechnical Service Information Fluid Level rp Checking/Changing Checking NOTE: (Check the fluid level with th temperature (the cooling fan c 1. Park the car on level ground. Shut off the engine. 2. Remove the dipstick (yellow loop) from the transmission and wipe it witha cloan cloth. 3. Insert the dipstick into the transmission. DIPSTICK (YELLOW LooP) 4. Remove the dipstick and check the fluid level. t should be between the upper and lower marks. |< upper ManK = Lower Mark 5. Ifthe level is below the lower mark, add fluid into the ‘tube to bring it to the upper mark. Use Honda Premium Formula Automatic Transmission Fluid or an equivalent DEXRON® Il Automatic Transmission Fluid (ATF) onty. 16. Insert the dipstick beck into the transmission. Changing 1. Bring the transmission up to operating temperature by driving the ear. Park the car on level ground, turn the fa cooler flusher is to be used, see page 14-128 and. 127. 2. Reinstall the drain plug with a new washer, then refil the transmission to the upper mark on the dipstick. ‘Automatic Transmission Fluid Capacity: 27 8129 US qt, 24 imp qi) at change 59 816.2 US qt, 52 imp at) st overhaul ‘TRANSMISSION RIGHT SIDE COVER ‘SEALING WASHER BRAIN PLUG Replece Tox 1Sem 50 Nm(60 kom, 36 bt)ATSG Technical Service Information Pressure Testing En 4, Start the engine and measure the respective press * While testing, be careful ofthe rotating tront wheels. ‘otows. Moke sure Wits, Jacks, and safety stands are placed ine Pressure properly Clutch Pressure + Ghtch Lowtigh Prossure ‘cauTioN ‘Throttle A/Thvottle B Pressure jefore testing, be sure the transmission fluid Is flled to *# Governor Pressure the proper level. 5. Install a new washer and the sealing bolt in the 1. Raise the car lnspection hole and tighten to the specified torque. 2, Warm up the engine {the cooling fan comes on), then TORQUE: 18 Nm/(1.8 kom, 13 bt) stop the engine and connect a tachometer, NOTE: 3. Connect the oll pressure gauge to each inspection hole Do not reuse old aluminum washers. ‘Line Pressure TORQUE: 18 Nem(1.8 kom, 13 ft) ‘Set the parking brake and block both rear wheels ‘caUTION securely. Connect the oll pressure gauge securely; be sure not to allow dust and other foreign particles to enter the —2 Run the engine at 2,000 rpm. Inapection hole. =3. Shift the soloct lever to[ N Jor[ P | positon. 4, Measure ine pressure. [AIT OIL PRESSURE GAUGE SET LINE PRESSURE INSPECTION HOLE AUT LOW PRESSURE GAUGE ‘97408--0070000" Lock.uP conTROL SOLENOID VALVE ASSEMBLY SELECTOR FLUID PRESSURE PRESSURE SYMPTOM | PROBABLE CAUSE POSITION Standard ‘Servic Limit Line NJor[P] | Notortow) | Torque converter, | 01887] 900-880 kPa | 750 kPa line pressure | ollpump pressure | engine | (80-85 kglem®, | (7.5 kg/cm? , regulator, torque 114—121 psi) 107 psi) ‘converter check valve, oll pump. p1626| 850-300 kPa | 800 kPa engine | (85-90 kglem*, | (80 kg/cm? , 121—128 psi) 114 psd NOTE: Higher pressures may be indicated if measurements are made in selector positions other than{ N]or{ P ] position (cont'd)Technical Service Information r (cont’d) ‘© Clutch Pressure Measurement While testing, be careful of the rotating front wheels. |. Set the parking brake and block both reer wheels securely. Raise the front of the car and support with sefety stands, Allow the front wheels to rotate freely. Run the engine at 2,000 rpm. Measure each clutch pressure. {1ST-HoLD CLUTCH PRESSURE INSPECTION HOLE “ATH CLUTCH prEssURE. INSPECTION HOLE” YY 22ND CLUTCH PRESSURE INSPECTION HOLE ‘67 CLUTCH PRESSURE: INSPECTION HOLE ‘3RD CLUTCH PRESSURE INSPECTION HOLETechnical Service Information #01887 engine ‘SELECTOR FLUID PRESSURE PRESSURE symptom | PROBARLE CAUSE POSITION Standard Service Limit yercuach | [iJor[De] | Noormow te | te Gurch 800-850 kPa | 760 kPa pressure BO-85 kolem?, | (78 kolem*, 14121 pa” | 167 pe Tethoid TA] [ soortow | terre cunen Guten ‘achold resture 2nd Catch [2] | Noortow | antcanch 2nd pressure 2nd Catch De Noorlow | rd Guach 4400 kPa 360 KPa 2nd pressure 40 kolem, | (35 kale, 57 psi 5 pak ‘rd Cuteh Noorlow | ardcutch {throtefuty trot futy See pressure osed) cosed) S050 kPa | 560'tPa “th Catch Noortow | athutch (80-85 koem*, | (78 kolem?, ‘th prosture 314-121 pel" | 107 pa (thre more than | (throttle mare then opened Bopened) ® Servo Vawveoratn | 00-850 KPa | 750 kPa Cutch (80-85 kgem?, | (78 Kalen?» Taiz psi _| Yor pon #01626 engine ‘SELECTOR FLUID PRESSURE PRESSURE symptom | PROBABLE CAUSE Postrion Standard Service Limit Tet Outch TJe[Be] | Noortow tet | ter Cutch @50-900 kPa | 600 KPa pressure (8.5-9.0 kgm’, | (8.0 kg/cm? , 121128 pal” | 114 ph Tethold 7 Noorlow | tevholé cuteh Guech fechold pressure 2nd Cutch 2 Noorlow | and curcn 2nd pressure Bnd Catch De Noortow | andGutch 400 kPa 350 KPa 2nd pressure (80 kolem®, | (28 kale, 57 pk 5 poh 2d Cutch Noorlow | eaCureh (throttle fy itor fy Bre pressure coved) coved) 850900 kPa | S00 kPa “th Cuch Noorlow | 4thGurtch {85-90 kate. | (80 kolem?, ‘th pressure 121128 pe (trot more than WBopenedd a Serve Valve or 4th | 850-900 KPa Cuch (85-80 kgem*, 121128 pa (cont'd)Technical Service Information r (cont‘d) Clutch Low/High Pressure Measurement While testing, be careful of the rotating front wheels. =1. Allow the front wheels to rotate freely. 2. Remove the cable end of the throttle control cable from the throttle control lever. Nore: Do not loosen the locknuts, simply unhook the cable end. ‘CABLE END ‘THROTTLE CONTROL LEVER 3, Start the engine and iat tie 4, Shite the lect lever to[ Ds | positon, =5. Slowly move the throttle linkage to increase engine ‘pm until prossure is indicated on the oll pressure seve. ‘Then relsase the throttle linkage, slowing the engine to return to an idle, and measure the pressure reading ‘THROTTLELINKAGE With the engine ting, It the throttle control lever roximately 1/2 of its possible travel and @ the engine rpm until pressure is indicated ‘gauge, then measure the highest pressure reading obtained. Repeat steps 6 and 6 for each clutch pressure being inspected. ‘THROTTLE CONTROL LEVERTechnical Service Information H CLUTCH PRESSURE ‘THROTTLE CONTROL LEVER INSPECTION HOLE” as < 2No CLUTCH PRESSURE INSPECTION HOLE ‘9RD CLUTCH PRESSURE INSPECTION HOLE oa EXHAUST PIPE +:D1587 engine ‘SELECTOR FLUID PRESSURE PRESSURE SYMPTOM | PROBABLE CAUSE POSITION | standard Service Limit 2nd Cluteh [04 No or low 2nd Clutch 400—850 kPa 350 kPa — 2nd pressure (40-85 kolom®, | (3.6 kolem* 57—121 psi 50 psi ‘rd Clutch ‘No or low 3rd Clutch varies with throttle | with throttle control 3rd pressur opening lever released 750 kPa | “ath Clutch No or low 4th Chtch (75 kglem* , ‘th pressure 107 ps ‘with throttle contrat lever more than 1/8 opened £01628 engine ‘SELECTOR FLUIO PRESSURE PRESSURE SYMPTOM | PROBABLE CAUSE POSITION Standard Service Limit 2nd Clutch ma No or low ‘2nd Clutch 400-900 kPa | 350 kPa = 2nd pressure (40-90 kglem®, | (3.5 kglem? , 57128 psd 50 psi 3rd Clutch No or low ‘ra Clutch varies with throttle | with throttle control_| 3rd pressure opening lever released 500 kPa 4th Chteh No or low ‘th Clutch (80 kg/em* , 4th pressure 114 pail with throttle controt lever more than 1/8 opened cont'd)Technical Service Information r (cont‘d) ‘Throttle A/Throttle B Pressure Measurement While testing, be careful of the rotating front wheels. 1, Allow the front wheels to rotate freely. 2 Remove the cable and of the throttle control cable from the throttle control lever. NOTE: Do not loosen the locknuts, simply unhook the cable end. 3. Shift the selector aver to[ Ds Jor{ Ba ] position. 4, Run the engine at 1,000 rpm. 5. Measure ful-closed throttle A/B pressure. —8. Move the throttle contrat lever to ful-opened throttle position. 7. Measure fultopened throttle A/B pressure. ‘THROTTLE A PRESSURE INSPECTION HOLE THROTTLE 8 PRESSURE. INSPECTION HOLE \ LY Lo Jf Xe Z AA EXHAUST PIPE Sah T SELECTOR PROBABLE FLUID PRESSURE PRESSURE ‘SYMPTOM POSITION CAUSE ‘Standard service Limit Throttle A. DeJor[Ds] | Pressuretoo | Throttle O—5 kPa high Valve A (0.08 kg/cm? 0.7 psi) — Modulator | throttle fullclosed valve Noor low 485-500 kPa 480 kPa ‘Throttle A (4.85—50 kolem? , (48 kglem?, pressure 89-71 psi) 68 psi) throttle full opened throttle full opened Throttle B DeJor[02] | Pressuretoo | Throttle 0-15 kPa high Valve & (0.18 kofem?, 21 psi — yottle ful closed ‘No orlow 1887] 900-850 kPa | 750 kPa Throttle B engine | (80-85 kolem*, | (7.5 kolem*, pressure 114—121 psi) 107 psi) throttle fulopened | throttle full opened 1626] 850-900 kPa | 800 kPa engine | (85-9.0 kalem*, | (8.0 kolem*, 121—128 psi) 114 psi) | throttle fullopened | throttle fullopenedTechnical Service Information ‘= Govornor Pressure Measurement EI While testin careful of the rotating front wheels. =1, Allow the front wheels to rotate freely =2, Runthe vehicle at 38 mph (60 kmh 3. Measure the governor pressure. GOVERNOR PRESSURE INSPECTION HOLE — EXHAUST PIPE ‘SELECTOR | Propaste FLUIO PRESSURE PRESSURE symptom | . POSITION |_ cause Standard [__ Service Limit Governor DeJor{ 0s] | Noor low Governor | 182—192 kPa 177 kPa — governor Valve (1.82—1.92 kglem? , (1.77 kotor, Pressure 26-27 psid 25 psi L_P4nTSG r Removal position on the engine ‘+ Apply parking brake and block rear wheels, so car will ‘ot roll off stands and fall on you while working undor i. CAUTION: Use fender covers to avoid damaging painted surfaces. 1. Disconnect the battery negative (—) and positive (+) cebles from the battery, 2. Remove the resonator, intake air duct and air cleaner housing. RESONATOR AIR CLEANER HOUSING Lg. weraxe an oucr nL Gc3 > 3, Remove the starter motor cables end cable holder from the starter motor ‘CABLE HOLDER STARTER CABLES STARTER MOT‘ Technical Service Information 4, Bs Transmission Remove the transmission ground cable from the transmission hanger. TRANSMISSION HANGER, TRANSMISSION GROUND CABLE Disconnect the lock-up control solenoid valve ‘connector. Lock-uP contROL SOLENOID VALVE CONNECTOR Lock-up conTROL ‘SOLENOID VALVE ASSEMBLYTechnical Service Information 6 2 Disconnect the vehicle speed sensor (VSS) connector vss CONNECTOR Remove the transmission housing mounting bolts and rear engine mounting bot REAR ENGINE MOUNTING BOLT , ‘TRANSMISSION HOUSING MOUNTING BOLTS. Remove the drain plug and drain the automatic, tranemigsion fluid (ATFI. Reinstall the drain plug with 2 new sealing wesher (see page 14-60). 9. Remove the cotter pins and castle nuts, then seperate the bal joints from the lower arm (see section 18) 10. Remove right damper fork bolt, then separate right damper fork and damper. Replace CASTLENUT COTTER PIN Rept DAMPER FORK igre side) 11, Pry the right and oft driveshafts out of the differential 12. Pullon the inboard joint and remove the right and left riveshafts (see section 16). 13, Tie plastic bags over the driveshaft ends. NOTE: Coat all precision finished surfaces with clean engine cil or grease. PLAsTICeAG (cont'd)TSG r Removal (cont'd) 14, Remove the splash shield. Gaskers Replace. EXHAUST PIPEA SELF-LOCKING nur Repco, Technical Service Information 6x 10. mmBOLT \ 16. Remove the exhaust pipe A. SELF-LOCKING nurs Roplece 16. Remove the shift cable cover, then remove the shift cable by removing the control lev ft control cable while CONTROL LEVER SHIFT CABLE COVER Lock WASHER Repiace 17. Remove the stopper mount, then remove the end of the throttle contro! cable from the throttle control lever. 18. Remove the ATF cooler hoses at the joint pipes. ‘Tum the ends of the cooler hoses up to prevent ATF from flowing out, then plug the joint pipes. NOTE: ‘Check for any signs of leakage at the hose joints. AFT COOLER HOSES STOPPER MOUNTTechnical Service Information 419, Remove the engine stiffeners and torque converter NOTE: Only the 01626 engine uses a rear engine stiffener. 20, Remove the 8 drive plate bolts one at a time while rotating the crankshaft pulley, DRIVE PLATE. ENGINE STIFFENER D16Z8 engine ony 2 a ENGINE STIFFENER ‘TORQUE CONVERTER, cover 21, Attach a hoisting bracket to the engine using the ‘distributor mounting bolt, then ift the engine sight. HOISTING BRACKET CHAIN HOIST DISTRIBUTOR 22. Place a jack under the transmission and raise the trasmission just enough to take weight off of the ‘mounts, then remove the transmission side mount. ‘TRANSMISSION Datloleeds SIDE MOUNT ‘MOUNTING BOLT 23. Remove the transmission housing mounting botts and rear engine mounting bots. 24, Pull the transmission away from the engine unti it clears the 14 mm dowel pins, then lower it on the tranemission jock. REAR ENGINE MOUNTING BOLTS i ‘SD TRANSMISSION HOUSING MOUNTING BOLTS TRANSMISSION JACKie ° < a £ L ° - € ® 2 > 2 0 oO @ 2 c £ ° o iE Illustrated Index Right Side CoverROLLER COLLAR O-RING Replace, FEED PIPE FLANGE 3RD CLUTCH FEED PIPE COUNTERSHAFT LOCKNUT (FLANGE NUT) Replace. PARKING GEAR ‘ONE-WAY CLUTCH ASSEMBLY COUNTERSHAFT 1ST GEAR NEEDLE BEARING COUNTERSHAFT 1ST GEAR COLLAR RIGHT SIDE COVER BREATHER COVER BREATHER CHAMBER GASKET Replace, BREATHER CHAMBER O-RINGS Replace. RIGHT SIDE COVER GASKET Replace. DOWEL PINS O-RING Replace. SSLOROIIOVOSESLODSOSESESHSSOOQEGNGHO Technical Service Information Seooosonoossesoanoqgseqqg|SNSSeSseS ‘1ST CLUTCH FEED PIPE O-RINGS Replace. FEED PIPE GUIDE cIRCLIP MAINSHAFT LOCKNUT FLANGE NUT) Replace 1ST CLUTCH ASSEMBLY O-RINGS Repl ‘THRUST WASHER ‘THRUST NEEDLE BEARING NEEDLE BEARING MAINSHAFT 1ST GEAR ‘THRUST WASHER MAINSHAFT 1ST GEAR COLLAR ‘1ST-HOLD CLUTCH FEED PIPE O-RING Replace. FEED PIPE GUIDE O-RING Replace. cIRCLIP ‘SUB-SHAFT LOCKNUT (FLANGE NUT) Replace. SUB-SHAFT DISC SPRING Replace, SUB-SAHFT 1ST GEAR ‘18T-HOLD ACCUMULATOR PISTON LOCK WASHER Repiace. ‘18T-HOLD ACCUMULATOR SPRING THROTTLE CONTROL LEVER O-RING Repiace. ‘THROTTLE CONTROL LEVER SPRING ‘18T-HOLD ACCUMULATOR COVER, OIL SEAL Replace. ‘SNAP RING ‘THROTTLE CONTROL CABLE HOLDER PARKING BRAKE PAWL ‘SEALING WASHERS Replace. PARKING BRAKE PAWL SPRING ‘ATF COOLER PIPE JOINT BOLT PARKING BRAKE PAWL SHAFT ‘ATF COOLER PIPES PARKING BRAKE PAWL STOPPER ATF LEVEL GAUGE PARKING BRAKE LEVER SPRING VEHICLE SPEED SENSOR PARKING BRAKE LEVER O-RING Replec PARKING BRAKE STOPPER ATF COOLER PIPE JOINT BOLT LOCK WASHER Replace. SEALING WASHERS Replace, DRAIN PLUG. SEALING WASHER Replace. TORQUE SPECIFICATIONS Ref No. Torque Value Bok Size Remarks A 12. Nem (1.2 kgm, 9 tot) 6x 1.0mm 8 14 Nim (1.4 kgm, 10 Bt), 6x 1.0mm ‘Special bolt c 11 Nm(1.1 kom, 8 Be) 8x 1.0 mm- D 22 Nem (2.2 kgm 16 Tb-ft 8x 1.25mm F 8 Nim (0.8 kgm, 58 lb-ft) 5xO8mm SG 29. Nm (29 kgm, 21 eft) 12% 1.25mm | ATF cooler pipe joint bok 1 50 Nem (50 kom, 36 tt) 18x 1.5mm Drain plug J 95 Nem (88 kgm, 69 Itt) 19x1.25mm ——_| Mainshaft locknut (flange nut): Lettshand threads } « 140 Nim (140 kgm, 101 bbe) > 0 > 23% 1.25 mm Countershatt iocknut 140 Nem (14.0 kgm, 101 tbe) (ange nut) L 95 Nem(9.5 kom, 69 b-tt) 19x1.25mm ——_| Sub-shaft locknut Ne {flange nut)3 “Sie ee0eeee © @ ° c 9 4 oO E S oO 2 Cc o 2 > fe oO oO 3 9 c £ oO o 2 Transmission Housing ATSGCOUNTERSHAFT REVERSE GEAR COLLAR NEEDLE BEARING ‘COUNTERSHAFT REVERSE GEAR LOCK WASHER Replace. REVERSE SHIFT FORK REVERSE SELECTOR REVERSE SELECTOR HUB COUNTERSHAFT 4TH GEAR NEEDLE BEARING DISTANCE COLLAR, 28 mm COUNTERSHAFT 2ND GEAR GOTTERS. ‘THRUST NEEDLE BEARING COUNTERSHAFT SRD GEAR NEEDLE BEARING ‘THRUST NEEDLE BEARING SPLINED WASHER Selective part ‘SRD CLUTCH ASSEMBLY ‘O-RINGS Replace. COUNTERSHAFT CIRCLIP THRUST SHIM ‘THRUST NEEDLE BEARING MAINSHAFT 4TH/REVERSE GEAR NEEDLE BEARINGS ATHIREVERSE GEAR COLLAR ‘THRUST NEEDLE BEARING THRUST SHIM 2ND/4TH CLUTCH ASSEMBLY O-RINGS Repiace. ‘THRUST WASHER, 36.5 x 51 mm Selective part ‘THRUST NEEDLE BEARING MAINSHAFT 2ND GEAR NEEDLE BEARING ‘THRUST NEEDLE BEARING S288 SEsQsssoRsgossasEssosEeseesagq000 Technical Service Information SeSVossoorssooonggcoesssas|ogCgcese MAINSHAFT SEALING RINGS, 35 mm SEALING RING, 29 mm NEEDLE BEARING SET RING ‘ST-HOLD CLUTCH ASSEMBLY O-RINGS Replace, THRUST SHIM ‘THRUST NEEDLE BEARING NEEDLE BEARING SUB-SHAFT 4TH GEAR THRUST NEEDLE BEARING SUB-SHAFT 4TH GEAR COLLAR SUB-SHAFT NEEDLE BEARING NEEDLE BEARING STOPPER OWL GUIDE CAP REVERSE IDLER GEAR SHAFT/HOLDER NEEDLE BEARING ‘STEEL BALL REVERSE IDLER GEAR SHAFT SPRING OIL SEAL Replace. THRUST SHIM, 86 mm Selective part TRANSMISSION HANGER. ‘TRANSMISSION MOUNT BRACKET REVERSE IDLER GEAR ‘TRANSMISSION HOUSING GASKET Replace. DOWEL PIN SNAP RINGS TRANSMISSION HOUSING SUB-SHAFT BEARING TRANSMISSION HOUSING MAINSHAFT BEARING ‘TRANSMISSION HOUSING COUNTERSHAFT BEARING ‘TRANSMISSION HOUSING DIFFERENTIAL ASSEMBLY OIL SEAL Replace TORQUE SPECIFICATIONS Ret No. Torque Valve Bon Size Remarks A 12 Nem (1.2 kom, 9 bf) 6x 1.0mm 8 14 Nim(1.4 kam, 10 Toft) 6x1.0mm ‘Special bok. E 34 Nim (84 kgm) 25 ft) 8x 1.25mm 4 50 Nem (50 kgm 36 Ib-ft) 12x 1.25mm. M 40 Nem (4.0 gem, 29 eft) 30x 1.5mm. Olt guide cap,Technical Service Information @4ATSG Torque Converter Housing/Valve Body(© ATF MAGNET Clean. ® ACCUMULATOR COVER ® G-AINGRepace @ OIL FEED PIPE ATE MAGNET Cian, SERVO DETENT BASE LOCK WASHERS Replace OIL FEED PIPE BAFFLE PLATE SERVO BOY. SERVO SEPARATOR PLATE THROTTLE CONTROL SHAFT ERING CHECK BALLS SECONDARY VALVE BODY DOWEL PINS SECONDARY SEPARATOR PLATE LOCK WASHERS Replce. oy essesesgqgqessesssesseoese Technical Service Information @ CSS 200 ogesssssososseseses@ REGULATOR VALVE BODY O-RING Replace. STATOR SHAFT STOPPER SHAFT CHECK BALLS DOWEL PINS MAIN VALVE BODY OIL FEED PIPE OIL FEED PIPE DOWEL PIN MAIN SEPARATOR PLATE lL PUMP DRIVE GEAR lL PUMP DRIVEN GEAR SHAFT lL PUMP DRIVEN GEAR CONTROL SHAFT DETENT SPRING DETENT ARM SHAFT DETENT ARM GOVERNOR BODY [ATF STRAINER Ciean or replace. DOWEL PIN ‘TORQUE CONVERTER HOUSING COUNTERSHAFT OIL FEED PIPE NEEDLE BEARING MODULATOR VALVE BODY OIL GUIDE PLATE DOWEL PINS TORQUE CONVERTER HOUSING MODULATOR SEPARATOR PLATE ‘TORQUE CONVERTER HOUSING MAINSHAFT LOCK-UP VALVE BODY BALL BEARING DOWEL PINS OIL SEAL Replace. LOCK-UP SEPARATOR PLATE LOCK-UP CONTROL SOLENOID VALVE ASSEMBLY TORQUE CONVERTER CHECK VALVE SPRING LOCK-UP CONTROL SOLENOID FILTER/GASKET TORQUE CONVERTER CHECK VALVE Replace. COOLER CHECK VALVE SPRING. OIL FEED PIPE ‘COOLER CHECK VALVE TORQUE SPECIFICATIONS Ret No. Torque Value Bot Size Remarks A 12 Nem(1.2 kom, 9 Ibe) 8x 1.0mm |Technical Service Information Right Side Cover r Removal a] NOTE: CCean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air low out all passages, When removing the transmission right side cover, replace the following: Right side cover gasket Lock washers O-rings Each shaft locknut + Dise spring + Sealing washers RIGHT SIDE COVER LockNuT RIGHT SIDE COVER GASKET isc SPRING tocknur 1ST CLUTCH ONE.WAY CLUTCH 1ST GEAR NEEDLE BEARING GEAR COLLAR, A PARKING BRAKE PAWL SHAFT owt Bott ATF COOLER PIPE _ OWT BOLT ATE LEVEL GAUGETechnical Service Information 1. Remove the 13 bolts securing the right side cover, then remove the cover. 2. Slip the special oo! onto the mainshatt. MAINSHAFT HOLDER 3. Engage the parking brake pawl! with the parking gear. 4. Align the hole of the sub-shaft 1st gear with the hole of the transmission housing, then insert a pin to lock the sub-shaft while removing the sub-shaft locknt. Pw Bm pn, sussart —commeriay isreean avaible PARKING GEAR ‘Aion the hoes. PARKING BRAKE PAWL 5. Pry the lock tabs of the mainshatt and countershaft locknuts. Cut the lock tab of the sub-shaft locknut using a chisel {88 shown. Then remove the locknut from each shaft. Nore: ‘Mainshaft locknut has left-hand threads, ‘Clean the old countershaft locknut, it is used to install the “press fit” parking ‘gear on the countershaft, + Always wear safety glasses, ‘CAUTION: Keep all of the chiseled particles out of the ‘transmission, cust sue.sHarT tocknuT 7. Remove the special tool from the mainshatt after removing the locknut, 8 Remove the Ist clutch and mainshaft tst gear ‘assembly from the mainshaft, 9. Remove the sub-shaft 1st gear. 10. Remove the parking brake paw, 11. Using @ universal two jaw pull, remove the parking gear, one-way clutch and countershaft Tet gear ‘assembly PARKING GEAR Prese-t type 12, Remove the parking brake lever from the control shaft. 13. Remove the throttle control lever from the throttle control shaft. 14, Remove the ATF cooler pipes. 15. Remove the ATF lever gauge.Technical Service Information [=] Transmission Housing ‘TRANSMISSION HOUSING BOLT MANGER ‘TRANSMISSION HOUSING ‘TRANSMISSION MOUNT BRACKET COLLAR NEEDLE BEARING ‘SHIFT FORK. REVERSE SELECTOR DIFFERENTIAL ASSEMBLYTechnical Service Information 88 thoroughly in solvent of carburetor cleaner and dry with compressed air. iow out all passages, ‘When removing the transmission housing, replace the folowing: Transmission housing gasket * Lock washer 1, Remove the transmission mount bracket. 2, Remove the transmission housing mounting bolts and hanger. 3. Align the spring pin of the control shaft with the transmission housing groove by turning the control shat. 44, Insta the special tool on the transmision housing, then rere housing as shown. HOUSING PULLER. OTHAC™PKAOTOA, SPRING PI 6 Remove the 5. Remove the countershatt reverse gear with the colar and needle bearing, lock bok securing the shift fork, then femove the fork with the reverse selector from the ‘countershaft. 7. Remove the countershaft and mainshaft sub-assembly together. MAINSHAFT: ‘counTeRsHAFT 8 Remove the differential assembly.Technical Service Information Torque Converter Housing/Valve Body r Removal MODULATOR VALVE OW FEED PIPE Booy Lock-uP VALE. ACCUMULATOR COVER BobY OIL FEED PIPE REGULATOR VALVE BODY STOPPER, SHAFT [STATOR SHAFT: £D on Fe 7 NY SECONDARY VALVE BODY Maun VALVE: BooY ou pump Driven’ (GEAR SHAFT ATF STRAINER ‘GOVERNOR BODYTechnical Service Information NOTE: Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air. * Blow out al passages. ‘= When removing the valve body replace the folowing: O-rings. + Lock washers 1. Remove the oil feed pipes from the servo body, modulator valve body and main valve body. 2, Remove the three bolts securing the accumulator cover, then remove the accumulator cover 3. Remove the three bolts securing the servo detent base, then remove the servo detent base and baffle plate, 4. Remove the four bolts securing the modulator valve body, then remove the modulator valve body and separator plate. ‘5. Remove the four bolts securing the servo body, then remove the servo body and separator plate 6. Remove the bolt securing the secondary valve body, then remove the secondary valve body and seperator plate. 7. Remove the seven bolts securing the lock-up valve body, then remove the lock-up valve body and separator slate. & Remove the bolt securing the regulator valve body, then remove the regulator vaive body. 9. Remove the stator shatt and stopper shaft, 10. 1" 12. 13, 4 18, 16. + Remove the detent spring from the detent arm, then femove the control shaft from the torque converter housing. Remove the detent arm and detent arm shaft from the main valve body, Remove the four bolts securing the main valve body, then remove the main valve body. Remove the oil pump driven gear shaft, then remove the oll pump gears, Remove the three bolts securing the governor body, ‘then remove the governor body. Remove the main separator plate with two dowel pins. Romove the ATF strainer.Technical Service Information Valve Caps r Description ‘Cops with one projected tip and one fiat end are installed ‘with the flat end toward the inside of the valve body. * Caps with a projected tip on each end are installed with the smaller tip toward the inside of the valve body. The small tip isa spring guide, of valve body. ‘Toward inside of valve body. ‘* Caps with one projected tip and hollow end are installed with the tip toward the inside of the valve body. The tip is aspring guide ‘Toward inside of valve body. * Caps with hollow ends are installed with the hollow end sway from the inside of the valve body. ‘*Caps with notched ends are instabed with the notch toward the inside of the valve body, ‘Caps with flat ends and a hole through the center are instaled with the smaller hole toward the inside of the valve body, Toward outside of valve body, SHoS ‘= Caps with flat ends and @ groove around the cap are installed with the groove side toward the outside of the valve body, Toward outside of valve body. croove Sections view. ‘Toward inside of valve body,Technical Service Information E] Valve Body - Repair NOTE: ‘This repair is only necessary if one or more of the valves in a vaive body do not side smoothly in thelr bores. You may Use this procedure to free the valves in the valve bodies, 1, Soak @ shest of #600 abrasive paper in ATF for about 30 minutes. Carefully tap the valve body so the sticking valve drops out ofits bore, CAUTION: Ht may be necessary to use a small screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver 3. Inspect the valve for any scuff marks. Use the ATF- ‘soaked #600 paper to polish off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed ait. 4. Rollup half a sheet of ATF-soaked paper and insert it in the valve bore of the sticking valve. Twist the paper slighty, so that i€ unrolls and fits the bore tightly, then polish the bore by twisting the paper 2 You push it in and out. CAUTION: The valve body Is aluminum and doesn’t require ‘much polishing to remove any burrs. ATF-sonked ———— Beco arngve nome SS Remove the #600 paper and thoroughly wash the entire valve body in solvent, then. dry with ‘compressed air. Coat the valve with ATF then drop it into ts bore. It should drop to the bottom of the bore under its own ‘weight. Ifnot, repeat step 4, then retest. valve VALVE BODY Remove the valve and thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then reassemble using ATF ae a lubricant,Technical Service Information + Install the valve, valve spring and cap in the valve body ‘and secure with the rol ROLLER sk -. ABsicer SEE So ORS SPRING VALVE BODY VALE cap So ROLLER cap SPRING: p Assembly Valve NOTE: + sett Cost ot pars with ATF before assemby Push spring sPaING. VALVE BODYTechnical Service Information crc ‘Slide the spring into the hole in the big end of the shift vaive. While holding the steel bals with the tins of your {ingers, put the sleeve over the shift valve. Place the shift spring in the shift valve, then slip it into the valve body and install the valve cover. sau sean se ur S - va Mi. sueeve VALVE COVER 5x08 mm 8 Nem (08 kom, 58 bf) * Installthe valve, spring and cap in the valve body. Push the cap, then instal the stopper seat. ‘STOPPER SEAT VALVE/SPRING capTechnical Service Information Main Valve Body r Disassembly/Inspection/Reassembly I parts thoroughly in solvent or carburetor cleaner and dry with compressed ai + Blow out all passages. * Replace valve body as an assembly f any parts are worn or damaged. ck all valves for free movement. any failto side freely, se0 Valve Body Repait ‘© Coat all parts with ATF before reassembly. ‘magnet to remove the check balls: it may magnetize the balls. s-ssnervaie at, CHECK BALLS oe G o Specs. 0: DETENT AM SHAFT le “Slag ce ene | 3-2 TIMING VALVE Des stiexiausr V7 Cae, TNE ; oO a serine sear 0 3 MANUAL VALVE RELIEF VALVE . ° bowel pv cap MAIN VALVE BODY 7 1-2sFT valve ® ROLLERTechnical Service Information rc cnecx sas A A A A Z i BZ ® Z Zz A crmcx BALL AMO MAIN VALVE BODY (Sectional View! (CHECK BALL. ® sono seeorcarions ott . ovina D | Relief vaive spring 1.10 (0.043) 8.60 (0.339) 37.10 (1.461) 13.4 @ | 4th exhaust vaive spring 0.90 (0.035) 6.60 (0.260) 43,30 (1.705) 20 @® | 2-3 shift valve spring 0.90 (0.035) 7.10 (0.280) 64,70 (2.547) 321 & | ESmnsete | Sees | Legh | ames | apart see | sere | EBC | tS @ | cams specs | seems | eee | es @D | 3—2timing vaive spring 1.20 (0.047) 8.60 (0.339) 46.90 (1.846) 15.2 @® | 1-2shift valve spring 0.4510.018 =| 5.10 10.201) 52.80 (2.079) | 20 8 [eases siese | 888) | Beem, | BeTechnical Service Information Oii Pump Inspection 1. Instat the ot pump gears and oil pump driven gear | 2 Measure the side clearance of the oil pump dive and Shaft nthe man veve body. Sven gars O11 Pump Gears Side (Radial) Clearance ‘Standard (New) : Drive gear (0.210—0.265 mm (0.0083—-0.0104 In) Driven go (0.0700.125 mm (0.0028-0.0048 in} on pumP DRIVEN GEAR, (Grooved and chamfered side ‘aces saperator pate, DRIVEN GEAR co pume Feet tet for wear or damage Shwe Gear Fapect tet or wear or deage ‘ox rum on pum | Brean onvencean’ | — i 2. Ramee th ol sum civn ger sats and manure the thrust elearance of the oll pump riven gear-to- ‘on. pume ee DRIVEN GEAR ioe cl Tl Ol pump Drive/Driven Gear thrust (Axial) Clearance 4 Standord (Now 10.08--0.08 mm (.001-0.002 in Service Limi \ ©1070 mem (0.0028 in MAIN VALVE BODYTechnical Service Information Regulator Valve Body assembly/Inspection/Reassembly NOTE: ‘+ Clean all parts thoroughiy in solvent or carburetor cleaner and dry with compressed ar. {Blow out all passages. Replace valve body as an assembly if any parts are worn or damaged. ‘Check all valves for free movement. I any falta side freely, see Valve Body Repair 1, Hold the regulator spring cap in place while removing the lock bol. Once the bolt is removed, release the spring cap slowly. CAUTION: ‘The regulator spring cap can pop out when the lock bolt is removed. 2. Reassembiy isin the reverse order of the disassembly procedure. Nore: ‘© Coat all parts with ATF. “Allan the hole in the regulator 5 ina cap with the hole in the valve body, press the spring cap into the body and tighten. reactor @ equLaTORVALVE @ ; Tongue convenrsn SERENE oc Locksour aS seer 2 12 nmi12 kgm, 9 bf) \ ‘ REGULATOR PANG CAP ® ROLLER REGULATOR VALVE BODY oN ~ J, we a ca Lockvecommmat wate VALVE SLEEVE ‘SPRING SPECIFICATIONS Unit of length : men fin) Standard (New) No, Spring Wire Dia 00, Free Length | No. of Coits @ | Reguiator valve spring A | 1.80(0071 |14.7010.579) |e860(34e0 | 165 ® | Regulator valve spring 8 1.801007) | 960(0.378) | 44.00(1.732) 75 ® | Stator resction spring 5.500.217) |*26.40 11.038)] 30.30 (1.193) 21 ® | Lock-up control valve spring 0.800.030) | 6.600.260) |50.60(1.992 | 24.6 ® | Cooler check vaive spring | 11010043) | 84010330 |33e011330 | 125 © | Torque converter check valve spring 11010043) | eaocoasn |3ae0i3an | 125 Inside DiameterTechnical Service Information Secondary Valve Body - Disassembly/Inspection/Reassembly CAUTION: Do not use a magnet to remove the check balls it may magnetize the balls, FILTER Repuce. CHECK BaLis Shes. SPRING SEAT GOVERNOR CUT VALVE cap ROLLER 4 © 4-3 KICK-DOWN VALVE ‘SECONDARY VALVE Boo’ bowel Pins 2pes. 2-1 TIMING VALVE Nr Ne 0 Pe, Pc VALVE STOPPER SEAT ‘SERVO CONTROL VALVETechnical Service Information Z o evecx sau. SECONDARY VALVE BODY Sectona view! ® SPRING SPECIFICATIONS Unit of length: | ‘Standard (New! | no. Soring 4 Wire Dia 00. Freetength | No.of Gols @ | 3-2kiek-down valve spring vs01005 | e60;0339 | 456011798 170 ® | 4 3kkkcdown valve srg ¥0010038) | 66010280) | 8801.17 7 ® | Governor aut vave sorng osoo0s | 76010209 | S480 (1754 170 & | 27Sertcecomraivaive spring | 10010038 | 66010260) | ae0tn.177 17 ® | 2-1 timing vaie spring 700028 | 8601020) | 330011280) ny | © | Roversecontolvove spring 07010028 | 71010280) | 400011575 208 ® | Servo control valve sprig Sg0(0089 | Gaoiozsm | serosa | 178 © | CetGiteh Pressure Contron | Oaoi00s) | B40l0.381 | 25.8011.008 at valve sng |Technical Service Information Servo Body r Disassembly/Inspection/Reassembly NOTE: * Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed ar. ‘Blow out all passages. ‘* Replace valve body as an assembly f any parts are worn or damaged, parts with ATF betore reassembly. ‘the O-rings and fters. * Fei ‘STH ACCUMULATOR PISTON ‘THROTTLE VALVE A 213-4 ORIFICE GonTROL VALVE VALVE SLEEVE THROTTLE CAM ® STOPPER 1ST ACCUMULATOR PISTON 6x1.0mm Do not remove or duet these nuts. 3RD ACCUMULATOR. PISTON. spring SEAT ‘SERVO VALVE! ‘SHIFT FORK SHAFT MODULATOR VALVE MODULATOR VALVE Bopy MODULATOR SEPARATOR PLATE bowel Piss Does. ‘2ND ACCUMULATOR PISTON onesTechnical Service Information [ ‘SPRING SPECIFICATIONS, Unit of length : mm tn} ‘Standard (New! No. Spring — Wire Dia, 00. Free Length No. of Cols @ | ardaccumulator spring 29000114 | 17.50(0.689) | &1.50(3.209) 139) ® | 2nd accumulator soring 35010138 | 220000866) | 75.40 (2968) a7 @ | Ast accumulator spring 26010103 | 24300957 | 7980142) a5 @ | 4th accumulator spring 28010110 | 16.00(0.630) | 85:00(3.346) 158 @ | 213~4 orifice control vaive spring | 3,00 0.039) 86010339) | §220(2055) 182 © | Modulator vaive spring 120008 |* 70010276 | 2720007 | 80 | Throttle vaive A adjusting spring | 0.80 (0.031) 62010244) | 27.00(1.063) 85 © | Throttle vaive A spring 41.10 (0.043) 85010335 | 2230/0878 at 1.00 (0.038) asoioass «| 222010874 | 60 4.10 (0.043) as0(0335 | 2230/0878 78 1.00 (0.039) 85010335 | 221010870) 55 @ | Throttle vaive 8 adjusting spring | 0.80 0.031) 62010244) | 30.00(1.181) 80 1 | Throttle vaive 8 spring 1.40 (0.055), 850(0335) | 41.50(1.834) 105 1.40 (0.088) 850(0335 | 41:50(1.634) nz | 1140 (0.058), 85010335) | 41.60(1.638) 124 * :Inside diameterTechnical Service Information Lock-up Valve Body r Disassembly/Inspection/Reassembly Note: ‘Clean al parts thoroughly in solvent or carburetor eleaner and dry with comprs ‘Blow out all passages. lve body as an assembly if any parts are worn oF damaged, ves for free movement, If any fallto Side freely, ee Vaive Body Repair * Cost ll parts with ATF before reassembly, Lock. uP SHIFT VALVE Lock-uP VALVE BODY Lock-UP TIMING B VALVE » @ ~~ J car DOWEL PINS ‘~ 2pcs. . ~~ 6 Ny [= SPRING SPECIFICATIONS Ut of nth min Standerd Now wo senna _ Wied | 0D. | Froetonah | Novei Com Sc 09010039 | 76010288 | 7570-2000 | s20 Sea dsoioaan | éeolozee: [erzozeen | aeTechnical Service Information Governor Body Disassembly/Inspection/Reassembly NOTE: * Clean all parts thoroughiy insolvent or carburetor cleaner and dry with compressed ar. + Blow out all passages. {Check that the governor works smoothiy; replace iti it does not. © Coat all parts with ATF before reassembly. 6x 1.0mm y cence (GOVERNOR HOUSING ASSEMBLY err VALVE Lock WASHER Replace. -/ FILTER Repice, WOODRUFF KEY, 3 mm GOVERNOR GEAR. cmcur ‘SPRING SPECIFICATIONS Unie of length : mm (in) ‘Standard (New) No. Spring 7 Wire Dia. 0.0. | FreeLength | No. of Coils ® | Governor spring A 1.00(0.039) | 18.80 (0.740) |32.9011.298) 44 ® | Governor spring 8 0190 (0.035) | 11.80 (0.465) | 27.80 1.094) 60 0,90 (0.038) | 11.80 (0.468) | 28.10 1.146) 60ATSG Technical Service Information 1st-hold Accumulator/Right Side Cover r Disassembly/Inspection/Reassembly NOTE: ‘* Clean all parts thoroughiy in solvent or carburetor leaner and dry with compressed ait. * Blow out al passages. *# Coat al parts with ATF before re sembly. ‘SNAP RING ‘1ST-HOLD ACCUMULATOR COVER Replace. (D1ST-HOLD ACCUMULATOR SPRING a | «a ‘1ST-HOLD ACCUMULATOR PISTON ‘O-RING Repoce. SPRING SPECIFICATIONS: Unit of length : mm in) ‘Standard (New) No. Spring Wire Dia, OD. Free Length | No.of Coils © | tet-hold accumulator spring [4.00(0.167 | 21.60 (0.846) | 71.70(2623) a3Technical Service Information Mainshaft , Disassembly/Inspection/Reassembly NOTE: ‘Lubricate all parte with ATF during reassembly. install the thrust need bearings with unrolled edge of bearing retainer facing washer. sspect the thrust needle bearings and the needle bearings for galing and rough movement. Before instaling the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings. * Locknut has left-hand threads. Locknur 3951.25 mm 35 NemiO'5 kom. 69 Bt) Lefehend thresds astewrcn \ ce a ASSEMBLY THRUST SHIM ones ‘THRUST NEEDLE Reploce BEARING’ z ‘THRUST WASHER ATHREVERSE GEAR —— trust neepue BEARING / gas NEEDLE BEARINGS. NEEDLE BEARING 1ST GEAR “STHREVERSE ‘GEAR COLLAR, — ‘THRUST WASHER scoring, setatches oF ‘THRUST NEEDLE BEARING 1ST GEAR COLLAR >> THRUST SHIM ~~ sransmission \ HOUSING BEARING 4. 2wovarh ciutcH ASSEMBLY ones THRUST WASHER, Replace 36.5%81 mm Selective port THRUST NEEDLE BEARING SEALING RINGS, deal 2ND GEAR ‘SEALING FING, NEEDLE BEARING 2am ‘THRUST NEEDLE memusesnne BEARING SET RING \Technical Service Information es | Inspection * Clearance Measurement NOTE: Lubricate al parts with ATF during assembly. 1. Remove the mainshaft be housing ring from the transmission 2, Assemble the parts below on the mainshaft. NOTE: Do not assemble the O-rings while inspecting. Locknur ‘1ST CLUTCH ASSEMBLY THRUST WASHER 1ST GEAR COLLAR, ‘TRANSMISSION. HOUSING BEARING THRUST SHIM TWREVERSE GEAR z couar gi ‘THRUST SHIM 2uovaTH cLuTCH ASSEMBLY THRUST WASHER, 365x851 mm Selective THRUST NEEDLE BEARING NEEDLE BEARING ‘THRUST NEEDLE BEARING Torque the mainshatt locknut to 30 Nem (2.0 kg-m, 22 et, NOTE: Mainshattlocknut has left-hand threads, aaa Lockwur 30 Nm (3.0 kom, 22 bet! Hold 2nd gear against the 2nd clutch, then measure the clearance between 2nd gear and Grd gear witha feeler the average as the actual clearance STANDARD: 0.05~0.13 mm (0.020.008 in) srogean JD GEAR falta Ty ir FEELER GAUGE" 2nD CLUTCH ‘THRUST wasHEn, 38.5% 811mm ‘39RD GEAR 2ND GEARTechnical Service Information THRUST WASHER 6, Select and install anew washer then recheck ‘THRUST WASHER 36.5 x 61 mm No. | Part Number Thickness: 1. | 90441~Pcs—010 | 3.50 mm (0.138 inl 2. | 90442—Pca—o10 | 3.55 mm (0.140 in) 3. | g0443—Pca—o10 | 3.60 mm (0.142 in) 4 | 90444—Pc9—o10 | 3.68 mm (0.144 in) 5 | s0445—Pc9-010 | 3.70 mmi0.146 in) 6 | 90446—Pc9—o10 | 3.78 mm (0.148 in) 7_ | 90447—Pc9—010 | 3.80 mm (0.160 in) 8 | 90648~Pc9~010 | 3.85 mm (0.182 in} 9 | 90489-Pca—o10 | 3.90 mm{0.154 int 7. After replacing the thrust washer, mal Clearance is within tolerance, sure theNore: DISTANCE COLLAR, 28 me Selctve pert corrers COUNTERSHAFT Technical Service Information p Disassembly/Inspection/Reassembly —————___ hock spines for excessive wear or damage Check bearing Surface for scoring scratches or excessive wear REVERSE SELECTOR ASTGEAR REVERSE a/ SELECTOR HUB g a NEEDLE BEARING 1ST GEAR COLLAR i mecots xan 5 TRANSMISSION HOUSING BEARING Courtershaft LOCKNUT, 23 x 1.25 mm 140 Nm (140 kom, 107 Bott 305 140 Nm 140 kom, 101 bet) REVERSE GEAR a PARKING GEAR NEEDLE BEARING ONE.Way CLUTCH IK REVERSE GEAR, Caen 3 2ND GEAR, ‘THRUST NEEDLE BEARING NEEDLE BEARING [THRUST NEEDLE BEARING ‘SPLINED WASHER Selective part ‘SRD CLUTCH ASSEMBLY ‘o-nines Rope.- Disassembly/Reassembly 1. Using a hydraulic press, press out the countershaft while supporting 4th gear. NOTE: Place an attachment between the press and the ‘countershaft to prevent damage to the shaft. CAUTION: Do not allow the countershaft to fall and hit the ‘round, PRESS ATTACHMENT ‘COUNTERSHAFT REVERSE SELECTOR mt Technical Service Information 2 Assemble the parts on the countershaft as shown below. NOTE: ‘ Lubricate all parts with ATF duting assembling, ‘ Bofore instaling the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings. AsTHGEAR NEEDLE BEARING DISTANCE COLLAR, 28 mm Sewctve 2ND GEAR corrers THRUST NEEDLE BEARING NEEDLE BEARING THRUST NEEDLE BEARING ‘COUNTERSHAFT {eont's)r Disassembly/Reassembly (cont'd) —4 3, Install the reverse selector hub on the countershatt sub-assembly, and then press the reverse selector hub Using the special tool and a press as shown, Press. DRIVER, 40 mm 1. (077860030700 REVERSE SELECTOR Hue CcounTERsHAFT SUB-ASSEMBLY Technical Service Information Countershaft - Inspection ‘= Clearance Measurement NOTE: Lubricate al parts with ATF during assembly. 1. Remove the countershaft bearing from the ‘transmission housing 2. Install the parts below on the countershaft using the ‘special ool and a press as described on this page. NOTE: Do not assemble the O-rings while inspecting. REVERSE SELECTOR fue ATHGEAR NEEDLE BEARING DISTANCE COLLAR, 28 mm Selective 2ND GEAR ‘THRUST NEEDLE BEARING corrers ‘3RD.GEAR NEEDLE BEARING ‘THRUST NEEDLE BEARING SSPLINED WASHER Sobctve ‘RD CLUTCH ASSEMBLY ‘COUNTERSHAFTATSG Technical Service Information 3, Install the parts below on the countershaft_sub- assembly, then torque the locknut to 30 Nm (3.0 kgm, 2ibrt Locknur 30 N10 kom, 22 BH) PARKING GEAR/1ST GEAR ONE-WAY CLUTCH ASSEMBLY NEEDLE BEARING 000 1ST GEAR COLLAR, ‘TRANSMISSION HOUSING BEARING REVERSE GEAR COLLAR COUNTERSHAFT ‘SUB-ASSEMBLY 4, Measure the clearance between the 4th gear and the reverse selector hub with a feeler gauge, Note: Take measurements in at least three places and take ‘the average as the actual clesrance. STANDARD: 0.05~0.13 mm (0.002—0.008 in} REVERSE ATHGEAR SELECTOR HUB DISTANCE COLLAR, _FEELER GAUGE DISTANCE COLLAR, 28mm REVERSE ‘SELECTOR HUB ATHGEARTechnical Service Information Countershaft r Inspection (cont'd) between 4th goer and reverse selector hub. Measure the clearance with Srd gear pushed towards 3rd ckitch. Mesure the clearance with 3rd gear pushed towards 2nd gear. NOTE: ‘Take measurements in at least three places and take the average as the actual clearance. 3. Subtract the measurements of step 2 from ind you have the clearance between 31d (9087 and 2nd gear, STANDARD: 0.05—0.13 mm (0.002—0.008 jn} STHGEAR 2ND GEAR 3RD GEAR REVERSE, SELECTOR HUS ‘ano curc# ‘ASSEMBLY, GRSEE —_Feeten cauce SPLINED WASHER, corren \ 6. Ifthe clearance is out of tolerance, remove the spined washer andior distance colar and measure the thickness and/or the width 7. Select and installa new distance collar, then recheck. DISTANCE COLLAR 28 mm No.| Part Number Thickness 1.| 90803—pce—o00 2| 90804—Pc9—000 38.00 mm (1.536 in) 39.10 mm (1.539 in) 3] 90505—Pc9—000 | 39.20 mm (1.543 in) 4 | 90507—PC9~000 | 39.30 mm (1.547 in) 8 | 90508-PC9—000 | 39.08 mm (1.537 in) 6 | 90509-Pca—000 | 39.15 mm (1.541 in) 7 90510-PC9~000 | 39.25 mm (1.545 in 8 | 90511-PC9—000 | 38.90 mm (1.531 in) 9] 90512-Pc9-000 38.95 mm (1.633 int & After replacing the distance collar, make sure the Clearance is within tolerance. 9. Select and installa new splined washer, then recheck. SPLINED WASHER 35 x 52 mm No.| Part Number Thickness 1. | 90411-PF4—000 | 3.00 mm {0.118 in} 2] 90412—PF4—000 90413—PF4—000 4 | 90414—PF4—000 3.05. mm (0.120 in} 3.10 mm (0.122 inl ‘3.18 mm (0.124 in DISTANCE COLLAR, ‘ 26 mm i u SRD GEAR 2ND GEAR 5 | 90815—PF4—000_ | 3.20 mm'0.126 in 6 | 90816—PF4—000 | 3.25 mm (0.128 in) 7 | 90817—PF4—000 | 3.30 mm (0.130 in) 8 | 90418—Pr4—000 | 3.35 mm (0.132 in) @ | 90819—PF4—000 | 3.40 mm (0.194 in} 10| 90411—P24—J00 | 3.45 mm (0.136 in} 11] 90412-P2¢—Jo0 | 3.50 mm (0.138 in) 10. After replacing the splined washer, make sure the Clearance is within tolerance.Technical Service Information One-way Clutch/Parking Gear - Disassembly and Inspection 1, Separate countershaft 1st gear from the parking gear Inspect the parts as folows: by turning the parking gear rection shown, PARKING GEAR weatemigee (LE Inspect the one-way atch for damage o, fauty movernont counrenswarr isrcean \\ 2. Remove the one-way clutch by prying it up with the Inspect counter- end of @ screwdriver. shaft T3t gear for ‘wear or seoring, COUNTERSHAFT 1STGEAR ONE-WAY CLUTCH NOTE: (—<—~_ instal inthis erection 3. After the parts are assembled, hold countershatt 1st {eer and turn the parking gear in the direction shown. tobe sure it turns freely. PARKING GEAR ‘COUNTERSHAFT 1ST GEAR ONE-WAY CLUTCH ‘COUNTERSHAFT 1ST GEAR /— screworwverTechnical Service Information Sub-shaft Disassembly/Inspection/Reassembly parts with ATF before reassembly. 2 thrust needle bearings with unrolled edge of bearing retainer facing wet ‘O-rings, 1. Remov Remov 3, Assemble the sub-shaft in the reverse order of removal. ‘TRANSMISSION HOUSING. S S —— [SNAP RING An a = ~~ ‘TRANSMISSION HOUSING BEARING 1sTHOLD CLUTCH ASSEMBLY 6x 1.0mm. T2Nmit2 kem.8 bt | ‘THRUST SHIM ‘THRUST NEEDLE BEARING’ NEEDLE BEARING ATH GEAR ‘THRUST NEEDLE 40 Nim (40 kom, 29 bet) BEARING ATHGEAR COLLAR NEEDLE BEARING- Replacement Technical Service Information Sub-shaft Bearings NOTE: Lubricate all parts with ATF before reassembly, 1, To remove the sub-shaft ball bearing from th transmission housing, expand the snap ring with ring piers, then push the bearing out using the special 1001s and a press as shown, river (07788-00100 SNAP RING ATTACHMENT, 62.68 mm ‘7748-0010500 2. Remove the needle bearing stopper. 3, Remove the needle bearing from the transmission housing using a drift punch, DRIFTIPUNCH 4. Install the new needle bearing in the transmission housing using the special tools and a press as shown. PRESS, river 0748~0010000 ATTACHMENT, 32 x35 mm a7748-0010100 8. Expand the snap ring with snap ring plier, then ineert the ball bearing part-way into the housing using the ‘special tools and a press as described in step 1. Install the Bearing with the groove facing outside the housing, 6. Release the pliers, then push the bearing down into the housing untithe snap ring snaps in place around t. 7. After instaling the ball bearing verify the folowing ‘= The snap ring is seated in the bearing and housing grooves. + The snap ring operates property. *# The ring end gap is correct. END GAP: 0-7 mm (002810) ‘SNAP RINGATSG Technical Service Information Clutch Iustrated Index 1ST CLUTCH cuurcH piss Standard thickness: SNAP RING 41188 mm (0.078 4) cimcur ‘SPRING RETAINER RETURN SPRING cLUTCH PISTON o-ninas Repiuce © v RUM CLUTCH END PLATE cuuTcHpLaTes Standard thewness: 11.60: mmm (0.063 i>) 3RD CLUTCH, cuutcHiscs Standard tnoxness: 1.94 ram (0076 in) (CLUTCH END PLATE ‘SNAP RING CLUTCH PISTON RETURN SPRING ‘SPRING RETAINER cmcur cuurcH tates. ‘Standard thewness 200 mm {0.079 in)TSG Technical Service Information 2noraTH CLUTCH cuurcH pisces cncu Standard tickness: 1.94 mm (0.076 inl (CLUTCH END PLATE / SNAP RING ‘SPRING RETAINER ( a " — cuuTcH PLATES Standard miekness: isc spring 200 710079 il 2ND CLUTCH RUM cLUTCH PISTON o-nines. Repace RETURN SPRING “LY RETURN SPRING Repiace. cLUTCH PLATES Standercthickness: CLUTCH PISTON 200 mm (0.078 In) ‘SNAP RING CLUTCH END PLATE guurcH oises ae tanderd tekress: 184 mm (0076 in athe ‘SPRING RETAINER (cont’aTechnical Service Information 1ST-HOLD CLUTCH SNAP RING CLUTCH END PLATE cuurcH PLATES Standard thickness: 200 mn (0.073 in) cmmcur SPRING RETAINER RETURN SPRING Disc SPRING / cLurcH PisTON cuuTH pisces Yy, Standard tiokness: é \ 1.84 mm (0076 in) Repace cLuTcH oRUM,Technical Service Information r Disassembly 1, Remove the snap ring, then remove the clutch end plat, clutch dises and plates, SCREWDRIVER 2. Remove the dise spring, Note: For 1st-hold, and 2nd clutches isc SPRING NX ‘2ND CLUTCH Disc sPAING 1ST-HOLD CLUTCH 3, Install the special tools as shown, LUTCH SPRING ‘Gompaesson ATTACHMENT ‘omae-Px80100 CLUTCH sprING CoMPaessoR ATTACHMENT ‘O7HAE—PLE0100 cuurcH serine COMPRESSOR BOLT ASSEMBLY O7GAE~PG80200 CLUTCH SPRING ComPaesson ATTACHMENT ‘Omae~Pxe0100 CLUTCH spAING CoMPaesson ATTACHMENT ‘O7HAE“PLEO100 CLUTCH SPRING ‘COMPRESSOR BOLT ASSEMBLY ‘O7GAE~PG80200 (cont’a)r Disassembly (cont'd) cAUTION: yer end of the compressor attachment is set over an. f the spring retainer which is unsupported by the ‘pring, the retainer may be damaged, Donat set here. 4. Compress the clutch return spring (CLUTCH RETURN SPRING Technical Service Information 5. Remove the circip. Then remove the special tools, ‘Spring retainer and return spring. cemcur 6. Wrap a shop towel around the clutch drum and apply air pressure to the oll passage to remove the piston. Place a finger tip on the other end while applying air pressure. OL PASSAGE COMPRESSED AIR HOSE NOZZLE OSHA-approved 20 pal ‘ype cay OW PASSAGETechnical Service Information - Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed at. + Blow out all passages. + Lubricate all parts with ATF before reassembly. 1. Inspect the check valve; it it’s loose replace the piston. Noe: Excopt 1st-hold clutch, (CHECK VALVE PISTON 2. Installnew O-rings on the clutch piston, 3, Be sure that the disc spring is securely staked. Nore: For 1st, 3rd and 4th clutches. Bi ones CLUTCH PISTON ‘O-RING 4, Install the piston in the clutch drum. Apply pressure {and rotate to ensure proper seating. NOTE: Lubricate the piston O-ring with ATF before instaling. ‘CAUTION: Do not pinch O-ring by instaling the piston with fore Piston =] 2 i cwrevonom 5. Install the return spring and spring retainer and position the citclp on the retainer. cmcur RETURN SPRING (cont'd)rp Reassembly (contd) 6. Install the special tools as shown, cLuTcH SPRING COMPRESSOR BOLT ASSEMBLY (O7GAe~PG80200 CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY ‘O7GAE~PG40200 CLUTCH SPRING COMPAESSOR ATTACHMENT ‘O7tAE~PX40100 CLUTCH SPRING COMPAESSOR ‘ATTACHMENT O7HAEPL50100 CLUTCH SPRING ComPaessor R / ‘ATTACHMENT ‘O7LAE—Pxa0100 CLUTCH SPRING ‘COMPRESSOR ‘ATTACHMENT ‘OTHAE~PLBO100 Technical Service Information 7. Setar. Do not set here ‘Compress the clutch return spring.Technical Service Information 4, Install the cick. 11, Soak the clutch discs thoroughly in ATF for @ minimum of 30 minutes. 12. Starting with @ clutch plat ‘clutch plates and discs. Install {lat side toward the disc nately install the {ch end plate with NOTE: Before instaling the plates and discs, make sure the Inside of the clutch drum is free of dirt or other foreign matter. comcuP 8. Remove the special tools 10. Installthe dise spring. NOTE: Discs AND PLATES For 1st-hold and 2nd clutches, install the dise spring in the direction shown. END PLATE 13. Install the snap ring. N\ axo curr isc SPRING eS) SCREWDRIVER \ S istouo ewutenReassembly (cont'd) 14, Measure the cissrance between the clutch end plate ‘Zero the dial indicator ine Ceorance between the cutch ond pate ‘and top disc. Technical Service Information 18. the clearance is not within the service mite, saloct a ‘new clutch end plate from the following tabe NOTE: If the thickest clutch ond plate is installed, but the Clearance is stil over the standard, replace the clutch Nore ‘Messure at three locations Chitch End Plate-to-Top Die Ci discs and clutch plates, 1ST, 2ND, 3RD and 4TH CLUTCH Plate No. | Part Number Thickness Clutch Service Limit tet 2nd Bea ath tetHold 0.65-0.85 mm (0.028—0.033 in) (0.65-0.85 mm (0.028—0.033 in) o40-* (0.50—0.80 mm (0.020—0.031 in) (CLUTCH END PLATE Top oisc 22551—PC9—000 22552—PC9-000 22553—PC9—000 22554—PC9—000 22555—PC9—000 19-000 22857—PC9—000 22558—PC9-000 22558—PC3—-000 22860—-PC8—000 22861—PC9—000 122562—PC3—000 13 | 22563-Pc9—000 H2seavomsen- 240 mm (0.094 in} 250 mm (0.088 in) 260 mm (0.102 in) 270 mm (0.106 in) 280 mm (0.110 in) 2.90 mm 0.114 in) | 3.00 mm (0.118 in) 3.10 mm (0.122 in) 3.20 mm (0.128 in) 3.20 mm (0-130 in} 2.10 mm (0.083 in} 2.20 mm (0.087 in) 230 mm (0.091 in} Thickness 18T-HOLD CLUTCH PlateNo. | Part Number 1 | 22651-Pss—003 2 | 22552~Pss—003 3 | 22563—PS5~—003 4 | 22654—Pss—003 5 No mark)| 22555—PS5—003 6 | 22556—PS5—003 7__| 22857—Ps5—003 2.10 mm (0.083 in) 220 mm (0.087 in) 230 ram (0.081 in) 2.40 mm (0.096 in) 250 mm (0.098 in) 2.60 mm (0.102 in) 2.70 mm (0.108 in) PLATE NUMBER { CLUTCH END PLATE~ Mainshaft Bearing Replacement 1. Drive out or pull up the meinshaft bearing and oil seal Using the special tools as shown. Driver 077880010000 ATTACHMENT 07347~€340500 TORQUE CONVERTER HOUSING. ‘YB in. x 16 threads/in. oN. SiseHbrmer Commerciaty Aylebie ADJUSTABLE BEARING BULLER. 25-40 mm (07736~A010008 Technical Service Information 2 3 Drive in the new mainshaft bearing until it bottoms in the housing, using the special tools as shown. DRIVER 07748-00100 ATTACHMENT, 62x68 mm (07746~-0010500 Install the new oil seal flush with the housing using the special tools as shown, DRIVER 07748~0010000ATSG Technical Service Information Torque Converter Housing Bearings Countershaft Bearing Replacement — 1, Remove the countershstt bearing using the special to0l. 18 nx 16 thread ‘Side Hammar Gommercialy Avababio 2, Installthe ol guide pate 3. Drive the new bearing into the housing using the special tools as shown. DIVER (077480010000 ATTACHMENT, 62.68 mm 07746~"0010500 0-0.03 mm {o-0.007 GUIDE PLATE”1 Technical Service Information Transmission Housing Bearings To remove the mainshatt and countershaft bearings from the transmission housing, expand each snap ring With snap ring pliers, then push the bearing out using ‘the special tools and a press as shown. NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing. ATTACHMENT, 62x68 mm 077480010500 MAINSHAFT BEARING oriver 07880010000 MAINSHAET ATTACHMENT, counrensHarT ATTACHMENT. ‘TRANSMISSION HOUSING. - Mainshaft/Countershaft Bearing Replacement 2 Expand each snap ring with snap ting pliers, insert the new bearing partway into the housing using the ‘Special tools and a press as shown, instal the bearing with the groove facing outside the housing NOTE: Coat ail parts with ATF. Release the pliers, then push the bearing down into the housing until the ring snaps in place around it. RIVER 077480010000 MAINSHART ‘ATTACHMENT, 722 76mm (7786~0010800 ‘COUNTERSHAFT ‘ATTACHMENT, 62x68mm 077460010800 After instaling the bearing verity the following: fing is seated in the bearing and housing ring operates properly. fend gap is correct. END GAP: 0-7 mm (0-028'n) SNAP RING- Installation 1, Set the spring in the reverse idler gear shaft. Push the spring in with the steel ball, then instal the needle bearing. NOTE: The steel ball is under spring pressure. Take care not toletit pop out. STEEL BALL 9, sas pe o me gs 2. Install the roverse idler gear REVERSE IDLER GEAR @) Technical Service Information Reverse Idler Gear 3, Install the reverse idler gear shaft holder into the ‘transmission housing, then tighten the bots. 6x10mm 12Nmit2 kom, 9 Bett) / REVERSE IDLER GEAR SHAFT HOLDER ASSEMBLY REVERSE IDLER GEAR Sectional View REVERSE IOLER GEAR, ‘TRANSMISSION HOUSINGATSG Technical Service Information n/Valve Body rp Reassembly parts with ATF. * Replace the parts below: ‘O-rings Lock washers Gaskets Locknute Spring washers MODULATOR Sealing washers. oureeD = VaLVEBODY TORQUE: 12 Nim (1.2 kom, 9 B-ft) Alboks ACCUMULATOR COVER 708 | ao Lote vaLvE BoDY —~— LU fe SEPARATOR PLATE aS Lock wasten f REGULATOR VALVE. an Bopy [STOPPER SHAFT. STATOR SHAFT. OL FEED Pres | ‘ MU ons } ‘SERVO BODY cova Docs. ‘SECONDARY VALVE BoDy’ MAIN VALVE BODY owe. pws ‘PUMP DRIVEN Bes GEAR SHAFT ‘SEPARATOR PLATE separator pate PUN Boke ATF STRAINER Lock WASHER ‘GOVERNOR BODY ‘TORQUE CONVERTER HOUSINGTechnical Service Information Installthe ATF strainer in the torque converter housing instal the main separator plate with two dowel pins on the torque converter housing. Then instal the oll pump drive gear, driven gear and driven gear shaft. NOTE: Install the oll pump driven gear with its grooved and ‘chamfered side facing down. ‘ou. pum / DRIVEN GEAR Groove CHAMFER on PUMP. DRIVE GEAR ou PUMP | _—Baiven'cean 1 pea on pump Driven’ — GEAR Grooved and chamteree ‘Bee faces separator pate, Loosely install the main valve body with four bolts. Make sure the oll pump erive gear rotates smoothly in the normal operating direction and the oll pump driven. ‘gear shaft moves smoothly in the axial and normal ‘operating directions. Instal the secondary valve body, separator plate and ‘two dowel pins with the bolt. Insta the control shaft in the housing, with the control shaft and manual valve together. Install the detent arm and arm shaft in the main valve body, then hook the detent spring to the detent arm. PY SERVO SEPARATOR PLATE conTRot MANUAL VALVE” un 2 13, 14, 18, 16, 1. Install the servo body and sepsrator plate with four bots. Install the modulator valve body, separator plate and two dowel pins with four botts. Install the accumulator cover with three bolts. Install the servo detent base and baffle plate with three bolts and new lock washers. Install the governor body with three bolts and new lock washers. Tighten the four bolts to 12.Nm (1.2 kgm, 9 bt) on the main valve body. "Make sure the oil pump drive gear and oil pump driven. (ar shaft move smoothly same as in the step 3. If the oil pump drive gear and oil pump driven gear shaft do not move freely, loosen the four bolts on the ‘main valve body and disassemble the valve bodies Realign the oil pump driven ges: shaft and reassemble the valve bodies, then retighten the bolts to the specified torque, CAUTION: Failure to align the oll pump ‘correctly will result in a seized oll pump drive get oll pump driven gear shaft. jen gear shatt cy OS sx DRIVE GEAR es DRIVEN GEAR Instal the stator shaft and stopper shaft. Insta the regulator valve body withthe bott. Install the lock-up valve bouy, separator plate and two Lowel pins with seven botts. Install the oll feed pipes. (cont'd)Technical Service Information Transmission/Transmission Housing rp Reassembly (cont'd) a ‘TRANSMISSION (MOUNT BRACKET ee 34 Nim(S4 kom, 25 Bett HOUSING BOLT 325mm 1241.25 mm. 50 Nmi60 kom, 38 Bett) COLLAR Mansnart———"} ‘SUB-ASSEMBLY REVERSE SELECTOR COUNTERSHAFT SUB-ASSEMBLY DIFFERENTIAL ASSEMBLYTechnical Service Information 18. a. Install the sub-shaft assembly in the transmission housing < Install the reverse idler gear and gear shaft holder Install the differential assembly in the torque converter housing. NOTE: Take care not to damas ‘the governor body. Install the mainshaft and countershaft sub- ‘together in the torque converter housing. sssembly MAINSHAET COUNTERSHAFT SUBLASSEMBLY ‘SUB-ASSEMBLY Turn the shift fork so the large chamfored hole is facing the fork bot hole, then instal the shift fork with the reverse selector and torque the lock bolt. Bend the lock tab against the bolt head, ‘SHIFT FORK J LOCK WASHER: val 8x 1.0mm 13 'Nem (14 kgm, 10 Bett Large chamfered hole SHIFT FORK. faces this way. SHAFT 23. Install the reverse gear with the collar and needle bearing on the countersha, 24, Align the spring pin of the control shaft with the transmission housing groove by turning the control shat. 25, Place the transmission housing on the torque ‘converter housing with a new gasket and the dowel Pins. SPRINGPIN CONTROL SHAFT Groove. TRANSMISSION HOUSING 26. Install the transmission housing bolts and transmission hhanger, then torque the bolts to 34 Nem (3.4 kom, 25 Ib-fein two of more steps as shown, 27. Install the transmission mount bracket on the transmission housing (cont'd)Technical Service Information Transmission/Right Side Cover MAINSHAFT HOLDER, ‘O7GAB-PF5OTOT 29, install the parking brake lever on the control shaft. 20. Install the parking gear, countershaft 1st gear and one: way clutch assembiy on the countershatt 31, Install the parking brake pawl in the transmission housing, then engage it with the parking gear. y Reassembly (cont'd) 28, Sip the special tool onto the mainshaft. 32, Use the old locknut to titan the press-fit paring ‘dear to the specified torque, then loosen i TORQUE: 140 Nim (14.0 kom, 101 fot) Locknut e- Geter PARKING GEAR Preset type 33, Install mainshaft 1st gear and 1st clutch assembly on the mainshaft. Then install sub-shaft Ist geer on the subsshatt. 34. Align the hole of the sub-shaft 1st gear with the hole of the transmission housing, then insert @ pin to lock the sub-shaft while tightening the sub-shaft locknut. 35. Install the disc spring on the sub-shaft, and new locknuts on each shaft. CAUTION: Insta the disc spring in the direction shown. 96. Tighten the locknuts to specified torque. ToRQuE: SMAINSHAFT 95 Nim (9.5 ko-m, 69 bt) UNTERSHAFT 140 Nem(14.0 kam, 101 b-ft) SUB-SHAFT 95 Nm(9.6 kom, 69 Ib-ft) bw MAINSHAFT commercaty Letenand Tocknur svalobe ‘oad mar _©& focenur: ASO ~STechnical Service Information 37, Stake each locknut using @ 3.5 mm punch, MAINSHAFT LOCKNUT Points tobe staked. Fange 1.2mm (0.08 nd ‘COUNTERSHAFT LOCKNUT 1.2mm (0.08 in} Point tobe staked. SUB-SHAFT LOCKNUT 98. Set the parking brake lever in th verity that the parking brake pi parking gear. 29. If the pawl does not engage fully, check the parking brake pawl stopper clearance as described 40, Tighten the lock bol and bend the lock tab, 6x 1.0mm 14 Nmit kom, 10 Bet PARKING GEAR PARKING BRAKE PAWL 41. Install the right side cover. TORQUE: 12 Nem (1.2 kom, 9 ib-fth 42. Install the ATF cooler pipes and nTF level gauge.Technical Service Information Parking Brake Stopper T Inspection/Adjustment 1. Set the parking brake lever in the[] position, 2. Measure the distance between the brake paw! shaft and face of the pa rol pin as shown. of the parking ing brake lever STANDARD: 67.25~68.25 mm (2.648—-2.687 in} ROLLER PIN PARKINGGEAR FAWL'SHART "PARKING BRAKE 3. If the measurement is out of tolerance, select and Install the appropriate parking brake stopper from the table below. PARKING BRAKE STOPPER, oat a u PARKING BRAKE STOPPER [Mark] Part Number be L 1 |24537—Pas—003] 11.00 mm | 11.00 mm (0.433 in) | (0.433 in) 2 |24838—PAS—003] 10.80 mm | 10.65 mm (0.425 in) | 0.419 in} 3, |24539-PA9—003] 10.60 mm | 10.30 mm (0.417 in} | (0.408 in} 4, After replacing the parking br the distance is within torelance.Technical Service Information Disassembly Torque Converter 6x 1.0mm 12 NmiT2 kom, 9 bet) 12x1.9mm 75 Nm(75 kom, 54 bet] Torque ia crisscross pattern, WASHER DRIVE PLATE. RING GEAR) ‘TORQUE CONVERTER ASSEMBLYTechnical Service Information Transmission r Installation ~ 1. Fush the ATF cooler as described on pages 14-125 5, Install the transmission side mount. thea 127. 1241.25 0m 2 Install the starter motor on the torque converter ‘TRANSMISSION 88 Nm(68 kom, 40 bf housing, then instal the 14 mm dowel pine in the SIDE MOUNT. torque converter housing MouNTING BOLTS AS Nmlas kom,29 Bh) STARTER MOTOR 142200 Sowa Ba 14%20 mm DowEL pn — O-RING Replace. 328125 mm ‘TOROUE CONVERTER 5 Nem (65 kom, 40 bet) 3, Place the transmission on a transmission jack, and 6. Install the remaining transmission housing mounting false to the engine level bolts and the remaining rear engine mounting bot. 4. Attach the transmission to the engine, then install wo transmission housing mounting bots and two rear REAR ENGR ‘engine mounting boks, ‘MOUNTING BOLT ax 1.25 mm REAR ENGINE 85 NmiB5 Kem, 61 bt) MOUNTING BOLTS Yan) 28 mm TRANSMISSION HOUSNG 8 NmIBS Kom, 61 BH) MOUNTING BOLTS. 12x 125mm 60 Nrn(6.0 kam, 43 Bt) NE MOUNTING BRACKET ‘TRANSMISSION HOUSING MOUNTING BOLTS 2x1 25mm BG MnO tom 43 tt 7. Remove the transmission jack and the hoist from the engine.Technical Service Information B { ‘Attach the torque converter to the drive plate with tight bolts snd torque to 12.N-m (t.2kg-m, 9 ib) Rotate the crankshaft as necessary to tighten the botts to 1/2 of the specified torque, then final torque, ina criss-cross pattern ‘After tightening the last bolt, check that the ‘crankshaft rotates freely. 9. Install the torque converter cover and engine stiffeners, NOTE: Only the D16Z6 engine uses a rear engine stiffener. 6x1.0mm HE Nmi12 kom. 9 bt /) Fo eH Ne DRIVE PLATE. FRONT ENGINE REAR ENGINE STIFFENER STIFFENER| DI6ZE engine onty 40% 128mm 45 Nem (45 kom, 33 Bit 1041.25 mm 45 "Nom (45 kom, 33 BH) 8x125mm 24 Nim (2 kom, 17 bt) 10. Connect the ATF cooler hoses to the join pipes. 11, Connect the throttle control cable and install the stopper mount THROTTLE (GABLE END \ ATE COOLER THRorTie. CONTROL a fever 10x 125mm 39.139 kom, 28 Bett) 121.25 mm 85 Nmi65 kom. 47 Bt) ‘STOPPER MOUNT 12. instal the control lever with @ new lock washer to the control shaft, then install the shift cable cover CAUTION: ‘Take care not to bend the shift cable. SHIFT CABLE Lock wasHER x Repiece. I SHIFT CABLE COVER 6x 1.0mm, AE NimIT4 kgm, 10 Rett) 8x 125mm ZA Nm(22 kom 16 bet) 13, Install the exhaust pipe A. GaskeTs epee SELF-LOCKING NUTS Replace 10% 125 mm 55 Nem (55 Kem, 40 bet) SELF-LOCKING NUTS Replce SELF-LocKINGNUTS 821.25 mm Replace 16 Nemi.6 kom, 12 bf) 85126 mm D2 Nimi22 kgm, 16 bet) (cont'd)Transmission r Installation (cont’d) 14, Installthe splash shield. 16. Install new set ring on the end of the each driveshaft. 16, Installthe right and left driveshafts (see section 16) NOTE: ‘Turn the right and left steering knuckle fuly outward, and side each driveshatt into the cifferential until you feelits spring clip engage the side gear. 17. Install the damper fork, then install the ball joint to the lower arm with new cotter pins. 1051.25 mm 44 Won (48 kom, 32 Bet sapsocnnowr \ es corren 12x 1.25 mm Repose. ™ 85 Wm Lem.47 bt) castignur see Esmm 35 mia wom. 40 Bt Technical Service Information 18. Connect the vehicle speed sensor (VSS) connector. ‘VSS CONNECTOR, 19. Connect the lock-up control solenoid connector, and clamp the harness on the lock-up control solenoid ‘connector stay. LOCK-UP CONTROL, ‘SOLENOID CONNECTOR Lock-uP conTRoL SOLENOID VALVE ASSEMBLYTechnical Service Information 20. Connect the transmission ground cable. “TRANSMISSION HANGER. ‘TRANSMISSION GROUND CABLE 21. Connect the starter motor cables on the starter motor, and install the cable holder NOTE: ‘When instaling the starter cable, make sure that the ‘crimped side of the ring terminal is facing out (see ‘section 23) [TERMINAL MOUNTING NUT CABLE HOLDER 9 Wm 103 kom, 65 BA) STARTER CABLES. 2, Install the air cleaner housing, intake sir duct and resonator, RESONATOR [AIR CLEANER HOUSING Refi the transmission with ATF (see page 14-50). Connect the battery positive (+) and negative (—) cables to the battery. (Check the ignition timing (see section 23). ‘Start the engine. Set the parking brake, and shift the ‘transmission through allgeers three times. Check for proper shift cable adjustment. Let the engine reach operating temperature_tthe cooing fan comes on with the transmission in[ Nor FF poston, then tr of and check thd love Road test as describedATSG Technical Service Information Shift Cable rp Removal/installation CAUTION: ‘AIL SRS electrical wiring harnesses are covered with Yellow outer insulation. * Before disconnecting ‘short connector (s} on * Replace the entire af ‘SRS MAIN HARNESS. Make sure lifts are placed properly 1. Remove the center console 2. ht [I] postion, than remove the lok pi rm ee ee Lock Nur 7 Wm (07 kom, 51 bet 8. Remove the shift cable bracket. 6x 108m 12 Nem(t2 kom, Bett) 4, Remove the shift cable holder. 5. Remove the shift cable cover. 6. Remove the control lever from the control shaft, then | Femove the shift cable. Take care not to bend the cable when removing/instaling it ‘SHIFT CABLE HOLDER 8x125mm SHIFT CABLE 22 Nimi22 kom, 16 bet LOCK WASHER Replace. 6x 1.0mm ‘CONTROL LEVER 12.Nemit2 kom, 9 Bett) 6x3.0mm 18 Nita kom, 10 Bet) 7. Installthe shift cable in the reverse order of removal & Check the cable adjustment on reassembly.Lock NuT 7m (0.7 kee, 6.1 bets SHIFT CABLE ADJUSTER Technical Service Information - Adjustment CAUTION: 4. Check thatthe hole inthe adjuster is perfectly afgned All SRS electrical wiring harn ‘with the hole inthe shift cable. There are two hols in Yollow outer insulation. the end of the shift cable. They are postoned 80" “sconnecting the SRS wire harness, apart to allow cable adjustment in 4 tum increment. ADWUSTER SHIFT CABLE 2 | cable able fxact Feo Short Feeteng Ragen ‘SRS MAIN HARNESS ection 1. 5. If not perfectv aged, loosen the locknut on the shift cable and adust as required 1, Start the engine. Shift to [F] postion to see if the reverse gear engages. I so, refer to troubleshooting 6. Tighten the locknut to 7 N-m (0.7 kg-m, 5 lb-ft). 7. instal the lock pin onthe adjuster. f you fel the lock pin binding es you reinstall, the cabo is til out of 2. With the engine off, remove the center console (see cjustment and must be readisted. ‘section 20), & Move the selector to each gear and verify that the automatic transaxle gear position inleatorfolows the shit to [A] potion, then remove the eck pin frm ‘xaos ananse ona silo cist 9. gine and check the shift lever in agers. f does not work properly, refer to ating 10. Insert the ignition key into the kev cylinder on the shift indicator panel, verify thet the shift lock lever is released.Technical Service Information Gearshift Selector r Disassembly/Reassembly CAUTION: “All SRS electrical wiring harnesses re covered with Yellow outer insulation. * Before disconnecting the SRS wire harness, install the short connector (a) on ‘Replace the entire affect hhas an open clrcut or damaged wiring. ‘SRS MAIN HARNESS _ LEVER KNOB Apply non heedening fread oek sealer SHIFT INDICATOR Pane Lock pmiRoD 5 Nm(O5 kom, 36 bt [AUTOMATIC TRANSAXLE GEAR POSITION SWITCH. SELECT LEVER BRACKET Testing. @ 12. Nmt12 kom, 9 bt) NN 10 Nem (1.0 kgm, 7 Beft)Technical Service Information Shift Indicator Panel > Adjustment CAUTION: SRS MAIN HARNESS 1. Check hat the index mark onthe ncator ans with the [1] mark onthe ait indietor panel when the transssion in NEUTRAL, 2. If not aligned, remove the center console, (see section 201 3. Remove the shift indicator panel mounting screws and ‘adjust by moving the panel the panel as described above. INDEX MARK MOUNTING SCREW 3.Nmi03 kom, 22 B40)Inspection Technical Service Information Throttle Control Cable NOTE: Before inspecting the throttle control cable, make sure: ‘Throttle cable free play is correct le speeds correct, '* To warm up the engine to normal operating temperature {the cooling fan comes on). 1. Verity that the throttle control lever is synchronized with the throttle linkage while depressing and releasing the accelerator pedal 2. I the throttle control lever is not synchronized with the throttle linkage, adjust the throttle control cable, ‘THROTTLE LINKAGE N / NS Q ‘THROTTLE CONTROL LEVER 3. Check that there is play while depressing the a throttle position. JO 18 throttle control lever ator pedal to the full 4. Remove the cable end of the throttie control cable from the throttle control lever. 5. Check that the throttle controllever moves smoothiy. (CABLE END- Adjustment Technical Service Information NOTE: Betore adjusting the throttle control cable, make sure: «Throttle cable free play is correct * Ke speed is correct ‘To warm up the engine to normal operating temperature {the cooling fan comes on). 1. Verify thet the throttle Enkage Is in the fulkclosed position. 2. Loosen the locknut of the throttle control cable at the throttle inkage. THROTTLE LINKAGE 3, Remove the free play of the throttle control cable with the locknut, while pushing the throttle control lever to fulkclosed position as shown. ‘THROTTLE CONTROL LEVER Pushin this dirction 4, Tighten the locknuts, 1 LOcKNUTS: '& After tightening the locknuts, inspect the synchroniza- tion and throttle control lever movernent.Technical Service Information Differential (Automatic Transmission) Illustrated Index Bout 10x 1.0 mm 103 Nom (10.3 kg-m, 74 ft) Lefthand threads BALL BEARING Replacement, page 15-12 Inspect for faulty movernent. FINAL DRIVEN GEAR Inspect for excessive weer. CARRIER SPEEDOMETER DRIVE GEAR [SNAP RING: BALL BEARING: Replscement, page 15-12 Inspect for faulty movement.Differential (Automatic Transmission) [- Backlash Inspection Place the differential assembly on V-biocks and in- stall both axles. 2. Check backlash of both pinion gears. ‘Standard (New): 0.05—0.18 mm (0.002—0.006 in) SIDE GEARS PINION GEARS. 3. If backlash is out of tolerance, replace the dfferen- tial carver. Technical Service Information r- Bearing Replacement NOTE: Check the bearings for wear and rough rotation. I the bearings are OK, removal is not necessary. 1. Remove the ball bearings using @ bearing puller BEARING PULLER BALL BEARING 2. Install the new ball bearings using the special tool fas shown. DRIVER, 40 mm 1.0, (07746-00010 BALL BEARING— Differential Carrier Replacement 1, Remove the final driven gear from the differential NOTE: The final driven gear bolts have left-hand threads. 2, Pry the snap ring off differentia carrier, then remove the speedometer drive gear and 5 x 10 mm roller. SNAP RING irFenenTiaL” ‘SPEEDOMETER ‘CARRIER DRIVE GEAR 3. Install the 5 x 10mm roller in the differential carrier. 4. Install the speedometer drive gear with its chamfered side facing the carrier. Align the cutout on the bore of the speedometer drive gear with the 5 x 10 mm roller. [SPEEDOMETER ‘DRIVE GEAR Italia this direction, Technical Service Information 5. Align the hooked end of the snap ring with the pin- ion shaft as shown, then instal the snap ting in the differential carrier groove. SNAP RING Install in thie direction Hooked end PINION SHAFT SPRING Pw ‘Groove 6. Install the final driven gear, then tighten the bolts specified torque. TORQUE: 103 Nem (10.3 kg-m, 74 lb-ft) NOTE: The final driven gear bolts have left-hand ‘thveads Bours 101.0 mm 103 Nem (10.3 kgm, ee 74 A Letthand threads FINAL DRIVEN GEAR Install n this direction DIFFERENTIAL CARRIER 7. Install the ball bearingsTechnical Service Information [— Oil Seal Installation/Side Clesrancey Install @ 2.50 mm (0.098 in} thrust shim in the trans ;- Oil Seal Removal Remove the differential assembly. 1 mission housing. NOTE: Do not install the oil seal yet. 1 Remove the oll seal from the transmission housing 2 ‘TRANSMISSION HOUSING ‘THRUST shin ‘TRANSMISSION HOUSING 2. Install the differential assembly into the torque con verter housing using the special tool as shown, on Seat Remove the oil seal from the torque converter DRIVER, 40 mm LD, 3 (07746--0030100, housing, DIFFERENTIAL, ‘ASSEMBLY ~~ “yoraue converter HOUSING 3. Assemble the transmission (see section 14). Install the transmission housing and tighten the bolts. TORQUE CONVERTER ic on sea Replace. HOUSINGTechnical Service Information 4, Tapon the transmission housing side of the differen- tial assembly with the special tool to seat the sifferential assembly inthe torque converter housing ee ze (077460030100 TOROUE CONVERTER HOUSING ‘5. Measure the clearance between the thrust shim and ‘outer race of the ball bearing in the transmission housing. STANDARD: 00.15 mm (0—0.006 in} ‘ToRauE ZN _ _ CONVERTER HOUSING PeELeR GAUGE 6. If out of limits, select a new thrust shim from the following table and install: THRUST SHIM, 80 mm Part Number Thickness (90414689000 | 2.60 mm (0.09843 in) 90415-68900 | 2.60 mm (0.10236 in} 90416683000 | 2.70 mm (0.10630 in) 90417689000 | 2:80 mm (0.11024 in) 90418683000 | 2.90 mm (0.11417 in) 90419-PH8—000 | 3.00 mm (0.11811 in) NOTE: If the thrust shim-to-ball bearing outer race ‘clearance measured in step 5is less than the specif cation, itis not necessary to perform steps 7 and & 7. Remove the transmission housing. 8. Replace the 2.50 mm (0,098 in) thrust shim with the one of the corract thickness selected in step 5. 8. Install the oil seal in the transmission housing using the special tools as shown, DRIVER (077490010000 ‘SEAL DRIVER. ATTACHMENT 07947--6110500 or (079476110501, puor, 26 x 30 mm 07JaD—PH80200 10. Install the oil seal in the torque converter housing using the special tools as shown, DRIVER 077430010000 ATTACHMENT 26 x30 mm (07JaD—-PHBO101 ‘07JaD-PHB0200